Download MULTIQUIP DCA125USI3CAN Specifications

Operation and Parts Manual
®
MODEL DCA125USI3CAN
60 hz generator
(ISUZU 4HK1X DIESEL ENGINE)
PARTS LIST NO. M3874400004, M3874400014
Revision #3 (12/19/14)
To find the latest revision of this
publication, visit our website at:
www.multiquip.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
fuel and chemical warnings
Diesel engine exhaust and some of
its constituents are know to cause
cancer, birth defects and other
reproductive harm.
page 2 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
Reporting Safety Defects
If you believe that your vehicle has a defect that could cause a crash or could
cause injury or death, you should immediately inform the National Highway
Traffic Safety Administration (NHTSA) in addition to notifying Multiquip Inc. at
1-800-421-1244.
If NHTSA receives similar complaints, it may open an investigation, and if it
finds that a safety defect exists in a group of vehicles, it may order a recall and
remedy campaign. However, NHTSA cannot become involved in individual
problems between you, your dealer, or Multiquip Inc.
To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free
at 1-888-327-4236 (TTY: 1-800-424-9153), go to http://www.safercar.gov; or
write to:
Administrator
NHTSA
400 Seventh Street, SW.,
Washington, DC 20590
You can also obtain information about motor vehicle safety from
http://www.safercar.gov.
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 3
Table of Contents
DCA125USI3CAN 60 Hz
Generator
Fuel And Chemical Warnings................................... 2
Reporting Safety Defects.......................................... 3
Table Of Contents..................................................... 4
Parts Ordering Procedures....................................... 5
Safety Information............................................... 6-11
Specifications......................................................... 12
Dimensions............................................................. 13
Installation......................................................... 14-15
General Information................................................ 16
Major Components................................................. 17
Generator Control Panel......................................... 18
Engine Operating Panel.................................... 20-21
Output Terminal Panel Familiarization............... 22-24
Load Application..................................................... 25
Generator Outputs.................................................. 26
Generator Outputs/Gauge Reading........................ 27
Output Terminal Panel Connections.................. 28-29
600 VAC Connections............................................. 30
Inspection/Setup................................................ 31-34
Generator Start-Up Procedure ......................... 35-36
Generator Shut-Down Procedures......................... 37
Maintenance...................................................... 38-41
Trailer Maintenance........................................... 42-59
Generator Wiring Diagram...................................... 60
600 VAC Auto Transformer Wiring Diagram............ 61
Engine Wiring Diagram........................................... 62
Controller Wiring Diagram...................................... 63
Battery Charger Wiring Diagram............................ 64
Jacket Water Heater Wiring Diagram...................... 65
Troubleshooting (Generator)................................... 66
Troubleshooting (Diagnostic Lamp)........................ 67
Explanation Of Code In Remarks Column............. 68
Suggested Spare Parts.......................................... 69
COMPONENT DRAWINGS
Generator Assembly.......................................... 70-71
Control Box Assembly....................................... 72-77
Engine And Radiator Assembly......................... 78-83
Output Terminal Assembly................................. 84-87
Battery Assembly.............................................. 88-89
Muffler Assembly............................................... 90-91
Fuel Tank Assembly........................................... 92-93
Enclosure Assembly Part 1................................ 94-97
Enclosure Assembly Part 2.............................. 98-101
Rubber Seals Assembly................................ 102-103
Battery Charger Assembly (Option).............. 104-105
Jacket Water Heater Assembly...................... 106-107
Nameplate And Decals Assembly................. 108-111
3Ø 600 Vac Transformer Assembly (Option). 112-113
Terms and Conditions of Sale — Parts................ 114
page 4 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
www.multiquip.com
Parts Ordering Procedures
Ordering parts has never been easier!
Choose from three easy options:
Order via Internet (Dealers Only):
Best Deal!
Effective:
January 1st, 2006
If you have an MQ Account, to obtain a Username
and Password, E-mail us at: parts@multiquip.
com.
Order parts on-line using Multiquip’s SmartEquip website!
■ View Parts Diagrams
■ Order Parts
■ Print Specification Information
To obtain an MQ Account, contact your
District Sales Manager for more information.
Use the internet and qualify for a 5% Discount
on Standard orders for all orders which include
complete part numbers.*
Goto www.multiquip.com and click on
Order Parts to log in and save!
Note: Discounts Are Subject To Change
Order via Fax (Dealers Only):
All customers are welcome to order parts via Fax.
Domestic (US) Customers dial:
1-800-6-PARTS-7 (800-672-7877)
Fax your order in and qualify for a 2% Discount
on Standard orders for all orders which include
complete part numbers.*
Note: Discounts Are Subject To Change
Order via Phone: Domestic (US) Dealers Call:
1-800-427-1244
Non-Dealer Customers:
Contact your local Multiquip Dealer for
parts or call 800-427-1244 for help in
locating a dealer near you.
International Customers should contact
their local Multiquip Representatives for
Parts Ordering information.
When ordering parts, please supply:
❒
❒
❒
❒
❒
❒
Dealer Account Number
Dealer Name and Address
Shipping Address (if different than billing address)
Return Fax Number
Applicable Model Number
Quantity, Part Number and Description of Each Part
❒ Specify Preferred Method of Shipment:
✓ UPS/Fed Ex
✓ DHL
■ Priority One
✓ Truck ■ Ground
■ Next Day
■ Second/Third Day
NOTICE
All orders are treated as Standard Orders and will
ship the same day if received prior to 3PM PST.
WE ACCEPT ALL MAJOR CREDIT CARDS!
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 5
Safety Information
Do not operate or service the equipment before reading the
entire manual. Safety precautions should be followed at all
times when operating this equipment. Failure to read and
understand the safety messages and operating instructions
could result in injury to yourself and others.
Potential hazards associated with the operation of this
equipment will be referenced with hazard symbols which
may appear throughout this manual in conjunction with
safety messages.
SaFetY meSSageS
The four safety messages shown below will inform you
about potential hazards that could injure you or others. The
safety messages specifically address the level of exposure
to the operator and are preceded by one of four words:
DANGER, WARNING, CAUTION or NotICe.
SaFetY SYmBolS
DANGER
Indicates a hazardous situation which, if not avoided,
WIll result in DEATH or SerIoUS INJUrY.
WARNING
Indicates a hazardous situation which, if not avoided,
CoUlD result in DEATH or SerIoUS INJUrY.
CAUTION
Indicates a hazardous situation which, if not avoided,
CoUlD result in mINor or moDerate INJUrY.
NOTICE
Addresses practices not related to personal injury.
page 6 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
Safety Information
geNeral SaFetY
CAUTION
„ Never operate this equipment without proper protective
clothing, shatterproof glasses, respiratory protection,
hearing protection, steel-toed boots and other protective
devices required by the job or city and state regulations.
„ Never operate this equipment when not
feeling well due to fatigue, illness or when
under medication.
„ Never operate this equipment under the influence of
drugs or alcohol.
„ Never use accessories or attachments that are not
recommended by MQ Power for this equipment. Damage
to the equipment and/or injury to user may result.
„ alWaYS know the location of the nearest
fire extinguisher.
„ alWaYS know the location of the nearest
first aid kit.
„ alWaYS know the location of the nearest
phone or keep a phone on the job site. Also, know the
phone numbers of the nearest ambulance, doctor and
fire department. This information will be invaluable in
the case of an emergency.
GENERATOR SAFETY
DANGER
„ alWaYS check the equipment for loosened threads or
bolts before starting.
„ DO NOT use the equipment for any purpose other than
its intended purposes or applications.
NOTICE
„ This equipment should only be operated by trained and
qualified personnel 18 years of age and older.
„ Whenever necessary, replace nameplate, operation and
safety decals when they become difficult read.
„ Manufacturer does not assume responsibility for any
accident due to equipment modifications. Unauthorized
equipment modification will void all warranties.
„ Never operate the equipment in an explosive
atmosphere or near combustible materials. An
explosion or fire could result causing severe
bodily harm or even death.
WARNING
„ Never disconnect any emergency or safety devices.
These devices are intended for operator safety.
Disconnection of these devices can cause severe injury,
bodily harm or even death. Disconnection of any of these
devices will void all warranties.
CAUTION
„ Never lubricate components or attempt service on a
running machine.
NOTICE
„ alWaYS ensure generator is on level ground before use.
„ alWaYS keep the machine in proper running condition.
„ Fix damage to machine and replace any broken parts
immediately.
„ alWaYS store equipment properly when it is not being
used. Equipment should be stored in a clean, dry location
out of the reach of children and unauthorized personnel
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 7
Safety Information
ENGINE SAFETY
DANGER
„ The engine fuel exhaust gases contain poisonous carbon
monoxide. This gas is colorless and odorless, and can
cause death if inhaled.
„ The engine of this equipment
requires an adequate free
flow of cooling air. Never
operate this equipment in
any enclosed or narrow area
where free flow of the air is
restricted. If the air flow is
restricted it will cause injury to people and property and
serious damage to the equipment or engine.
WARNING
„ DO NOT place hands or fingers inside engine
compartment when engine is running.
„ Never operate the engine with heat shields or
guards removed.
„ Keep fingers, hands hair and clothing away
from all moving parts to prevent injury.
„ DO NOT remove the radiator cap while the
engine is hot. High pressure boiling water
will gush out of the radiator and severely
scald any persons in the general area of
the generator.
„ DO NOT remove the coolant drain plug while the engine
is hot. Hot coolant will gush out of the coolant tank and
severely scald any persons in the general area of the
generator.
„ DO NOT remove the engine oil drain plug while the
engine is hot. Hot oil will gush out of the oil tank and
severely scald any persons in the general area of the
generator.
CAUTION
„ Never touch the hot exhaust manifold,
muffler or cylinder. Allow these parts to cool
before servicing equipment.
NOTICE
„ Never run engine without an air filter or with a dirty air
filter. Severe engine damage may occur. Service air filter
frequently to prevent engine malfunction.
„ Never tamper with the factory settings
of the engine or engine governor. Damage
to the engine or equipment can result
if operating in speed ranges above the
maximum allowable.
„ Wet stacking is a common problem with diesel engines
which are operated for extended periods with light or
no load applied. When a diesel engine operates without
sufficient load (less than 40% of the rated output), it will
not operate at its optimum temperature. This will allow
unburned fuel to accumulate in the exhaust system,
which can foul the fuel injectors, engine valves and
exhaust system, including turbochargers, and reduce
the operating performance.
In order for a diesel engine to operate at peak efficiency,
it must be able to provide fuel and air in the proper ratio
and at a high enough engine temperature for the engine
to completely burn all of the fuel.
Wet stacking does not usually cause any permanent
damage and can be alleviated if additional load is
applied to relieve the condition. It can reduce the system
performance and increase maintenance. Applying an
increasing load over a period of time until the excess
fuel is burned off and the system capacity is reached
usually can repair the condition. This can take several
hours to burn off the accumulated unburned fuel.
„ State Health Safety Codes and Public Resources
Codes specify that in certain locations, spark arresters
must be used on internal combustion engines that use
hydrocarbon fuels. A spark arrester is a device designed
to prevent accidental discharge of sparks or flames
from the engine exhaust. Spark arresters are qualified
and rated by the United States Forest Service for this
purpose. In order to comply with local laws regarding
spark arresters, consult the engine distributor or the
local Health and Safety Administrator.
page 8 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
Safety Information
FUel SaFetY
DANGER
„ DO NOT start the engine near spilled fuel or combustible
fluids. Diesel fuel is extremely flammable and its vapors
can cause an explosion if ignited.
„ Make sure the hitch and coupling of the towing vehicle
are rated equal to, or greater than the trailer “gross
vehicle weight rating.”
„ alWaYS inspect the hitch and coupling for wear. Never
tow a trailer with defective hitches, couplings, chains, etc.
„ alWaYS refuel in a well-ventilated area, away from
sparks and open flames.
„ Check the tire air pressure on both towing vehicle and
trailer. Trailer tires should be inflated to 50 psi cold.
Also check the tire tread wear on both vehicles.
„ alWaYS use extreme caution when working with
flammable liquids.
„ alWaYS make sure the trailer is equipped with a safety
chain.
„ DO NOT fill the fuel tank while the engine is running
or hot.
„ alWaYS properly attach trailer’s safety chains to towing
vehicle.
„ DO NOT overfill tank, since spilled fuel could ignite if it
comes into contact with hot engine parts or sparks from
the ignition system.
„ alWaYS make sure the vehicle and trailer directional,
backup, brake and trailer lights are connected and
working properly.
„ Store fuel in appropriate containers, in well-ventilated
areas and away from sparks and flames.
„ DOT Requirements include the following:
„ Never use fuel as a cleaning agent.
„ DO NOT smoke around or near the
equipment. Fire or explosion could result
from fuel vapors or if fuel is spilled on a
hot engine.
TOWING SAFETY
CAUTION
„ Check with your local county or state safety
towing regulations, in addition to meeting
Department of Transportation (DOT)
Safety Towing Regulations, before towing
your generator.
„ Refer to MQ Power trailer manual for additional safety
information.
„ In order to reduce the possibility of an accident while
transporting the generator on public roads, alWaYS
make sure the trailer that supports the generator and
the towing vehicle are mechanically sound and in good
operating condition.
„ alWaYS shutdown engine before transporting
•Connectandtestelectricbrakeoperation.
• Secure portable power cables in cable tray with tie
wraps.
„ The maximum speed for highway towing is 55 mph unless
posted otherwise. Recommended off-road towing is not to
exceed 15 mph or less depending on type of terrain.
„ Avoid sudden stops and starts. This can cause skidding,
or jack-knifing. Smooth, gradual starts and stops will
improve towing.
„ Avoid sharp turns to prevent rolling.
„ Trailer should be adjusted to a level position at all times
when towing.
„ Raise and lock trailer wheel stand in up position when
towing.
„ Place chock blocks underneath wheel to prevent rolling
while parked.
„ Place support blocks underneath the trailer’s bumper
to prevent tipping while parked.
„ Use the trailer’s swivel jack to adjust the trailer height to
a level position while parked.
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 9
Safety Information
eleCtrICal SaFetY
DANGER
„ DO NOT touch output terminals during
operation. Contact with output terminals
during operation can cause electrocution,
electrical shock or burn.
„ The electrical voltage required to
operate the generator can cause severe
injury or even death through physical contact with live
circuits. Turn generator and all circuit breakers OFF
before performing maintenance on the generator or
making contact with output terminals.
„ Never insert any objects into the output
receptacles during operation. This is
extremely dangerous. The possibility exists
of electrical shock, electrocution or
death.
„ Backfeed to a utility system can cause
electrocution and/or property damage.
Never connect the generator to a
building’s electrical system without
a transfer switch or other approved
device. All installations should be
performed by a licensed electrician in accordance with
all applicable laws and electrical codes. Failure to do so
could result in electrical shock or burn, causing serious
injury or even death.
„ Make sure power cables are securely connected to the
generator’s output receptacles. Incorrect connections
may cause electrical shock and damage to the
generator.
NOTICE
„ alWaYS make certain that proper power or extension
cord has been selected for the job. See Cable Selection
Chart in this manual.
Grounding Safety
DANGER
„ alWaYS make sure that electrical circuits are properly
grounded to a suitable earth ground (ground rod) per
the National Electrical Code (NEC) and local codes
before operating generator. Severe injury or death by
electrocution can result from operating an ungrounded
generator.
„ Never use gas piping as an electrical ground.
power Cord/Cable Safety
DANGER
„ Never let power cords or cables lay in water.
„ Never stand in water while AC power from the
generator is being transferred to a load.
„ Never use damaged or worn cables or cords when
connecting equipment to generator. Inspect for cuts in
the insulation.
„ Never grab or touch a live power
cord or cable with wet hands. The
possibility exists of electrical shock,
electrocution or death.
page 10 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
Safety Information
BatterY SaFetY
DANGER
„ DO NOT drop the battery. There is a possibility that the
battery will explode.
„ DO NOT expose the battery to open flames,
sparks, cigarettes, etc. The battery contains
combustible gases and liquids. If these
gases and liquids come into contact with a
flame or spark, an explosion could occur.
WARNING
eNvIroNmeNtal SaFetY
NOTICE
„ Dispose of hazardous waste properly.
Examples of potentially hazardous waste
are used motor oil, fuel and fuel filters.
„ DO NOT use food or plastic containers to
dispose of hazardous waste.
„ DO NOT pour waste, oil or fuel directly onto the ground,
down a drain or into any water source.
„ alWaYS wear safety glasses when handling
the battery to avoid eye irritation. The battery
contains acids that can cause injury to the
eyes and skin.
„ Use well-insulated gloves when picking up the battery.
„ alWaYS keep the battery charged. If the battery is not
charged, combustible gas will build up.
„ alWaYS recharge the battery in a well-ventilated
environment to avoid the risk of a dangerous concentration
of combustible gasses.
„ If the battery liquid (dilute sulfuric acid) comes into
contact with clothing or skin, rinse skin or clothing
immediately with plenty of water.
„ If the battery liquid (dilute sulfuric acid) comes into
contact with eyes, rinse eyes immediately with plenty
of water and contact the nearest doctor or hospital to
seek medical attention.
CAUTION
„ alWaYS disconnect the NegatIve battery terminal
before performing service on the generator.
„ alWaYS keep battery cables in good working condition.
Repair or replace all worn cables.
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 11
Specifications
Table 1. Generator Specifications
Model
DCA125USI3CAN
Revolving field, self ventilated,
Type
open protected type synchronous generator
Armature Connection
Star with Neutral
Zigzag
Phase
3
1
Standby Output
110 kW (137.5 kVA)
79 kW
Prime Output
100 kW (100 kVA)
72 kW
3Ø Voltage (L-L/L-N)
208Y/120, 220Y/127,
N/A
Voltage Selector Switch at 3Ø 240/139
240Y/139
3Ø Voltage (L-L/L-N)
416Y/240, 440Y/254,
N/A
Voltage Selector Switch at 3Ø 480/277
480Y/277
1Ø Voltage (L-L/L-N)
N/A
240/120
Voltage Selector Switch at 1Ø 240/120
Power Factor
0.8
1.0
Frequency
60 Hz
Speed
1800 rpm
Aux. AC Power
Single Phase, 60 Hz
Aux. Voltage/Output
120V/4.8 Kw (2.4 kW x 2)
Sound Level dB (A)
65
Full Load at 23 ft. (7.0 Meters)
Dry Weight
5,689 lbs. (2,580 kg)
Wet Weight
7,012 lbs. (3,180 kg)
Table 2. Engine Specifications
Model
ISUZU 4HK1XYGD-03 Tier 3
4 cycle, water-cooled, direct injection, turbocharged,
Type
air to air intercooled
No. of Cylinders
4 cylinders
Bore x Stroke
4.53 in. x 4.92 in. (115 mm x 125 mm)
Displacement
317 cu. in. (5193 cc)
Rated Output
152 HP/1800 RPM
Starting
Electric
Coolant Capacity
5.2 gal. (19.7 liters)
Lube Oil Capacity
6.1 gal. (23.4 liters)
Fuel Type
#2 Diesel Fuel
Fuel Leak Warning Capacity
42.3gal. (160 liters)
Fuel Tank Capacity
169 gal. (640 liters)
5.7 gal. (21.7 L)/hr at 3/4
7.3 gal. (27.6 L)/hr at full load
load
Fuel Consumption
4.0 gal. (15.1 L)/hr at 1/2 load 2.4 gal. (9.1 L)/hr at 1/4 load
Battery
12V-128 Ah x 1
page 12 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
Dimensions
Figure 1. Dimensions
Table 3. Dimensions
Reference
Letter
Dimension in. (mm)
Reference Letter
Dimension in. (mm)
A
38.20 in. (970 mm.)
F
120.10 in. (3,050 mm.)
B
37.00 in. (940 mm.)
G
73.00 in. (1,855 mm.)
C
36.20 in. (920 mm.)
H
48.80 in. (1,200 mm.)
D
37.00 in. (940 mm.)
E
3620 in. (920 mm.)
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 13
Installation
GENERATOR
GROUND LUG
GROUND ROD FOR
EARTH GROUND.
CONNECT TO BUILDING
GROUND IF APPLICABLE
GROUND CABLE
.
4M
REFERENCE
NEC 250-83 (C)
T./2
8F
I
(M
M)
U
NIM
Figure 2. Typical Generator Grounding Application
page 14 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
Installation
Outdoor Installation
Generator Grounding
Install the generator in a area that is free of debris,
bystanders, and overhead obstructions. Make sure the
generator is on secure level ground so that it cannot slide
or shift around. Also install the generator in a manner so
that the exhaust will not be discharged in the direction of
nearby homes.
To guard against electrical shock and possible damage to
the equipment, it is important to provide a good EARTH
ground.
The installation site must be relatively free from moisture
and dust. All electrical equipment should be protected from
excessive moisture. Failure to do will result in deterioration
of the insulation and will result in short circuits and
grounding.
Foreign materials such as dust, sand, lint and abrasive
materials have a tendency to cause excessive wear to
engine and alternator parts.
CAUTION
Pay close attention to ventilation when operating the
generator inside tunnels and caves. The engine exhaust
contains noxious elements. Engine exhaust must be
routed to a ventilated area.
Indoor Installation
Exhaust gases from diesel engines are extremely
poisonous. Whenever an engine is installed indoors the
exhaust fumes must be vented to the outside. The engine
should be installed at least two feet from any outside wall.
Using an exhaust pipe which is too long or too small can
cause excessive back pressure which will cause the engine
to heat excessively and possibly burn the valves.
Article 250 (Grounding) of the National Electrical Code
(NEC) provides guide lines for proper grounding and
specifies that the cable ground shall be connected to the
grounding system of the building as close to the point of
cable entry as practical.
NEC articles 250-64(b) and 250-66 set the following
grounding requirements:
1. Use one of the following wire types to connect the
generator to earth ground.
a. Copper - 10 AWG (5.3 mm2)
b. Aluminum - 8 AWG (8.4 mm2)
2. When grounding the generator (Figure 2) connect the
ground cable between the lock washer and the nut on
the generator and tighten the nut fully. Connect the
other end of the ground cable to earth ground.
3. NEC article 250-52(c) specifies that the earth ground rod
should be buried a minimum of 8 ft. into the ground.
NOTICE
When connecting the generator to any buildings
electrical system ALWAYS consult with a licensed
electrician.
Mounting
The generator must be mounted on a solid foundation (such
as concrete) and set firmly on the foundation to isolate
vibration of the generator when it is running. The generator
must set at least 6 inches above the floor or grade level (in
accordance to NFPA 110, Chapter 5-4.1). DO NOT remove
the metal skids on the bottom of the generator. They are
to resist damage to the bottom of the generator and to
maintain alignment.
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 15
General Information
Generator
Open Delta Excitation System
This MQ Power Model generator (Figure 3) is a high quality
portable (requires a trailer for transport) power source for
telecom sites, lighting facilities, power tools, submersible
pumps and other industrial and construction machinery.
This generator is equipped with the state of the art “OpenDelta” excitation system. The open delta system consist
of an electrically independent winding wound among
stationary windings of the AC output section.
There are four connections of the open delta A, B, C and
D. During steady state loads, the power from the voltage
regulator is supplied from the parallel connections of A to
B, A to D, and C to D. These three phases of the voltage
input to the voltage regulator are then rectified and are the
excitation current for the exciter section.
When a heavy load, such as a motor starting or a short
circuit occurs, the automatic voltage regulator (AVR)
switches the configuration of the open delta to the series
connection of B to C. This has the effect of adding the
voltages of each phase to provide higher excitation to the
exciter section and thus better voltage response during the
application of heavy loads.
The connections of the AVR to the AC output windings are
for sensing only. No power is required from these windings.
The open-delta design provides virtually unlimited excitation
current, offering maximum motor starting capabilities. The
excitation does not have a “fixed ceiling” and responds
according the demands of the required load.
Engine Operating Panel
The “Engine Operating Panel” is provided with the following:
„„Tachometer
„„Water Temperature Gauge
„„Warning Lamp
„„Pre-Heat Lamp
„„Oil Pressure Gauge
„„Charging Ammeter Gauge
„„Fuel Level Gauge
„„Fuel Leak Detection Lamp
„„Panel Light/Panel Light Switch
„„ECU Controller
„„Engine Speed Switch
„„Warning Lamp (Diagnostic Lamp)
Generator Control Panel
The “Generator Control Panel” is provided with the following:
„„Frequency Meter (Hz)
„„AC Ammeter (Amps)
„„AC Voltmeter (Volts)
„„Ammeter Change-Over Switch
„„Voltmeter Change-Over Switch
„„Voltage Regulator
„„3-Pole, 350 amp Main Circuit Breaker
„„“Control Box” (located behind the Gen. Control Panel)
•Automatic Voltage Regulator
•Current Transformer
•Over-Current Relay
•Starter Relay
•Voltage Selector Switch
•Diagnostic Switch
Output Terminal Panel
The “Output Terminal Panel” is provided with the following:
„„Three 120/240V output receptacles (CS-6369), 50A
„„Three auxiliary circuit breakers, 50A
„„Two 120V output receptacles (GFCI), 20A
„„Two GFCI circuit breakers, 20A
„„Five output terminal lugs (3Ø power)
„„Low Coolant Level Switch
„„Battery Charger (Optional)
„„Jacket Water Heater
„„Camlock Connector (Option)
„„600 VAC Output Auto-Transformer (Option)
Engine
This generator is powered by a 4 cylinder, water cooled,
direct injection, turbocharged ISUZU 4HK1X diesel engine.
This engine is designed to meet every performance
requirement for the generator. Reference Table 2 for engine
specifications.
In keeping with MQ Power’s policy of constantly improving
its products, the specifications quoted herein are subject
to change without prior notice.
Electric Governor System
The electric governor system controls the RPMs of the engine.
When the engine demand increases or decreases, the
governor system regulates the frequency variation to ±.25%.
Extension Cables
When electric power is to be provided to various tools or
loads at some distance from the generator, extension cords
are normally used. Cables should be sized to allow for
distance in length and amperage so that the voltage drop
between the generator and point of use (load) is held to
a minimum. Use the cable selection chart (Table 6) as a
guide for selecting proper extension cable size.
page 16 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
Major Components
Table 4. Generator Major Components
ITEM NO.
DESCRIPTION
1
Muffler Assembly
2
Engine Assembly
3
Enclosure Assembly
4
Generator Assembly
5
Output Terminal Assembly
6
Fuel Tank Assembly
7
Battery Assembly
8
Generator Operating Panel Assembly
9
Engine Control Panel Assembly
Figure 3. Major Components
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 17
Generator Control Panel
Figure 4. Generator Control Panel
The definitions below describe the controls and functions
of the Generator Control Panel (Figure 4).
1. Main Circuit Breaker—This three-pole, 350A main
breaker is provided to protect the U,V, and W Output
Terminal Lugs from overload.
2. Voltage Regulator Control — Allows ±15% manual
adjustment of the generator’s output voltage.
Located behind the generator control panel is the Generator
Control Box. This box contains some of the necessary
electronic components required to make the generator
function.
The Control Box is equipped with the following major
components:
„„Over-Current Relay
3. Ammeter Change-Over Switch — This switch allows
the AC ammeter to indicate the current flowing to the
load connected to any phase of the output terminals,
or to be switched off. This switch does not effect the
generator output in any fashion, it is for current reading
only.
„„Automatic Voltage Regulator (AVR)
4. Voltmeter Change-Over Switch — This switch allows
the AC voltmeter to indicate phase to phase voltage
between any two phases of the output terminals or to
be switched off.
„„Main Circuit Breaker
5. Frequency Meter — Indicates the output frequency in
hertz (Hz). Normally 60 Hz.
6. AC Ammeter — Indicates the amount of current the
load is drawing from the generator per leg selected by
the ammeter phase-selector switch.
7. AC Voltmeter — Indicates the output voltage present
at the U,V, and W Output Terminal Lugs.
„„Starter Relay
„„Current Transformer
„„Voltage Selector Switch
NOTICE
Remember the overcurrent relay monitors the current
flowing from the U,V, and W Output Terminal Lugs
to the load.
In the event of a short circuit or over current condition,
it will automatically trip the 350 amp main breaker.
To restore power to the Output Terminal Panel, press
the reset button on the overcurrent relay and place the
main circuit breaker in the closed position (ON).
page 18 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
Notes
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 19
ENGINE OPERATING PANEL
Figure 5. Engine Operating Panel
page 20 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
ENGINE OPERATING PANEL
and all major faults will shutdown the generator. During
cranking cycle, the ECU will attempt to crank the engine
for 10 seconds before disengaging.
The definitions below describe the controls and functions
of the Engine Operating Panel (Figure 5).
1. Panel Light — Normally used in dark areas or at night
time. When activated, panel lights will illuminate. When
the generator is not in use be sure to turn the panel
light switch to the OFF position.
If the engine does not engage (start) by the third
attempt, the engine will be shutdown by the engine
controller’s Over Crank Protection mode. If the engine
engages at a speed (RPM's) that is not safe, the
controller will shutdown the engine by initializing the
Over Speed Protection mode.
Also the engine controller will shut down the engine in
the event of low oil pressure, high coolant temperature,
low coolant level, and loss of magnetic pickup. These
conditions can be observed by monitoring the LED
status indicators on the front of the controller module.
2. Panel Light Switch — When activated will turn on
control panel light.
3. Preheat Lamp — As the engine cranks, this lamp
will illuminate to indicate automatic preheating of
the engine glow plugs. When the lamp turns off, this
indicates that the preheat cycle is complete and the
engine will start automatically.
4. Warning Lamp (Diagnostic Lamp) — When lit
indicates a that a failure has occurred in the engine
control system.
5. Fuel Leak Detection Lamp — This lamp will illuminate
when a leak in the fuel tank containment enclosure is
detected.
6. Engine Speed Switch — This switch controls the
speed of the engine (low/high).
A. MPEC Control Switch — This switch controls the
running of the unit. If this switch is set to the OFF/
RESET position, the unit will not run. When this switch
is set to the manual position, the generator will start
immediately.
8. Water Temperature Gauge — During normal operation
this gauge be should read between 167°~203°F (75°
~95°C).
If the generator is to be connected to a building’s
AC power source via an automatic transfer switch
(isolation), place the switch in the AUTO position. In this
position, should an outage occur, the automatic transfer
switch (ATS) will start the generator automatically
via the generator’s auto-start contacts connected to
the ATS’s start contacts. Please refer to your ATS
installation manual for further instructions for the
correct installation of the auto-start contacts of the
generator to the ATS.
9. Charging Ammeter Gauge — Indicates the current
being supplied by the engine’s alternator which
provides current for generator’s control circuits and
battery charging system.
B. Low Oil Pressure — Indicates the engine pressure
has fallen below 15 psi (103 kPa). The oil pressure is
detected using variable resistive values from the oil
pressure sending unit. This is considered a major fault.
10. Fuel Gauge — Indicates amount of diesel fuel
available.
C. High Coolant Temperature — Indicates the engine
temperature has exceeded 230°F (110°C). The engine
temperature is detected using variable resistive values
from the temperature sending unit. This is considered
a major fault.
7. Oil Pressure Gauge — During normal operation this
gauge should read between 42 ~71 psi. (290~490 kPa).
When starting the generator the oil pressure may read
a little higher, but after the engine warms up the oil
pressure should return to the correct pressure range.
11. Tachometer — Indicates engine speed in RPM’s for
60 Hz operation. This meter should indicate 1800
RPM’s when the rated load is applied. In addition a
built in hour meter will record the number of operational
hours that the generator has been in use.
12. Auto START/STOP Engine
Controller (ECU) — This controller
has a vertical row of status LED's
(inset), that when lit, indicate
that an engine malfunction (fault)
has been detected. When a fault
has been detected the engine
controller will evaluate the fault
D. Overcrank Shutdown — Indicates the unit has
attempted to start a pre- programmed number of
times, and has failed to start. The number of cycles and
duration are programmable. It is pre-set at 3 cycles with
a 10 second duration. This is considered a major fault.
E. Overspeed Shutdown — Indicates the engine is
running at an unsafe speed. This is considered a
major fault.
F. Engine Running — Indicates that engine is running
at a safe operating speed.
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 21
OUTPUT TERMINAL PANEL FAMILIARIZATION
Output Terminal Panel
Output Terminal Familiarization
The Output Terminal Panel (Figure 6) shown below is
located on the right-hand side (left from control panel) of
the generator. Lift up on the cover to gain access to
receptacles and terminal lugs.
The “Output Terminal Panel ” (Figure 6) is provided with
the following:
„„Three 120/240V output receptacles @ 50 amp
NOTICE
„„Three Circuit Breakers @ 50 amps
Terminal legs “O” and “Ground” are considered bonded
grounds.
„„Two 120V GFCI receptacles @ 20 amp
„„Two GFCI Circuit Breakers @ 20 amps
„„Five Output Terminal Lugs ( U, V, W, O, Ground)
Figure 6. Output Terminal Panel
page 22 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
OUTPUT TERMINAL PANEL FAMILIARIZATION
120 VAC GFCI Receptacles
There are two 120 VAC, 20 amp GFCI (Duplex Nema
5-20R) receptacles provided on the output terminal panel.
These receptacles can be accessed in any voltage
selector switch position. Each receptacle is protected by a
20 amp circuit breaker. These breakers are located directly
above the GFCI receptacles. Remember the load output
(current) of both GFCI receptacles is dependent on the
load requirements of the U, V, and W output terminal lugs.
Pressing the reset button resets the GFCI receptacle after
being tripped. Pressing the test button (Figure 7) in the
center of the receptacle will check the GFCI function. Both
receptacles should be tested at least once a month.
Each auxiliary receptacle is protected by a 50 amp circuit
breaker. These breakers are located directly above the
GFCI receptacles. Remember the load output (current) on
all three receptacles is dependent on the load requirements
of the output terminal lugs.
Turn the voltage regulator control knob (Figure 9) on the
control panel to obtain the desired voltage. Turning the knob
clockwise will increase the voltage, turning the knob
counter-clockwise will decrease the voltage.
Figure 9. Voltage Regulator Control Knob
Removing the Plastic Face Plate (Hard Wire
Hookup Panel)
The output terminal lugs are protected by a plastic face
plate cover (Figure 10). Unscrew the securing bolts and
lift the plastic terminal cover to gain access to the terminal
enclosure.
After the load wires have been securely attached to the
terminal lugs, reinstall the plastic face plate.
Figure 7. G.F.C.I. Receptacle
Twist Lock Dual Voltage 120/240 VAC Receptacles
There are three 120/240V, 50 amp auxiliary twist-lock (CS6369) receptacles (Figure 8) provided on the output
terminal panel. These receptacles can only be accessed
when the voltage selector switch is placed in the singlephase 240/120 position.
Figure 10. Plastic Face Plate
(Output Terminal Lugs)
Figure 8. 120/240V Twist-Lock
Auxiliary Receptacles
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 23
OUTPUT TERMINAL PANEL FAMILIARIZATION
Connecting Loads
Over Current Relay
Loads can be connected to the generator by the output
terminal lugs or the convenience receptacles (Figure 11).
Make sure to read the operation manual before attempting
to connect a load to the generator.
An over current relay (Figure 12) is connected to the main
circuit breaker. In the event of an overload, both the circuit
breaker and the over current relay may trip. If the circuit
breaker can not be reset, the reset button on the over
current relay must be pressed. The over current relay is
located in the control box.
To protect the output terminals from overload, a 3-pole, 350
amp main circuit breaker is provided. Make sure to switch
ALL circuit breakers to the OFF position prior to starting
the engine.
Figure 12. Over Current Relay
Figure 11. Connecting Loads
page 24 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
Load Application
Single Phase Load
Three Phase Load
Always be sure to check the nameplate on the generator
and equipment to insure the wattage, amperage, frequency,
and voltage requirements are satisfactorily supplied by the
generator for operating the equipment.
When calculating the power requirements for 3-phase
power use the following equation:
Generally, the wattage listed on the nameplate of the
equipment is its rated output. Equipment may require
130—150% more wattage than the rating on the nameplate,
as the wattage is influenced by the efficiency, power factor
and starting system of the equipment.
NOTICE
If wattage is not given on the equipment’s name plate,
approximate wattage may be determined by multiplying
nameplate voltage by the nameplate amperage.
WATTS = VOLTAGE x AMPERAGE
The power factor of this generator is 0.8. See Table 5 below
when connecting loads.
Table 5. Power Factor By Load
Type of Load
Power Factor
Single-phase induction motors
0.4-0.75
Electric heaters, incandescent lamps
Fluorescent lamps, mercury lamps
Electronic devices, communication
equipment
Common power tools
1.0
0.4-0.9
Load in Watts
At 100
Volts
2.5
5
0.8
Maximum Allowable Cable Length
At 200
Volts
#10 Wire
#12 Wire
#14 Wire
#16 Wire
300
600
1000 ft.
600 ft.
375 ft.
250 ft.
600
1200
500 ft.
300 ft.
200 ft.
125 ft.
7.5
900
1800
350 ft.
200 ft.
125 ft.
100 ft.
10
1200
2400
250 ft.
150 ft.
100 ft.
15
1800
3600
150 ft.
100 ft.
65 ft.
2400
4800
125 ft.
75 ft.
50 ft.
20
If 3Ø load (kVA) is not given on the equipment
nameplate, approximate 3Ø load may be determined
by multiplying voltage by amperage by 1.732.
NOTICE
Motors and motor-driven equipment draw much greater
current for starting than during operation.
An inadequate size connecting cable which cannot carry the
required load can cause a voltage drop which can burn out
the appliance or tool and overheat the cable. See Table 6.
„„When connecting a resistance load such as an
incandescent lamp or electric heater, a capacity of up
to the generating set’s rated output (kW) can be used.
„„When connecting a fluorescent or mercury lamp, a
capacity of up to the generating set’s rated output (kW)
multiplied by 0.6 can be used.
„„When connecting an electric drill or other power tools,
pay close attention to the required starting current
capacity.
1.0
Table 6. Cable Selection (60 Hz, Single Phase Operation)
Current
in
Amperes
NOTICE
When connecting ordinary power tools, a capacity of up to
the generating set’s rated output (kW) multiplied by 0.8 can
be used.
DANGER
Before connecting this generator to any building’s
electrical system, a licensed electrician must install
an isolation (transfer) switch. Serious damage to
the building’s electrical system may occur without this
transfer switch.
CAUTION: Equipment damage can result from low voltage
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 25
GENERATOR OUTPUTS
Generator Output Voltages
Generator Amperage
A wide range of voltages are available to supply voltage for
many different applications. Voltages are selected by using
the voltage selector switch (Figure 13). To obtain some of
the voltages as listed in Table 7 (see below) will require a
fine adjustment using the voltage regulator (VR) control
knob located on the control panel.
Table 8 shows the maximum amps the generator can
provide. DO NOT exceed the maximum amps as listed..
Table 8. Generator Maximum Amps
Rated Voltage
Voltage Selector Switch
1Ø 120 Volt
The voltage selector switch (Figure 13) is located above
the output terminal panel’s Hard Wire Hook-up Panel. It
has been provided for ease of voltage selection.
1Ø 240 Volt
Maximum Amps
277.8 amps (4 wire)
301A x 2 (Zigzag)
138.9 amps (4 wire)
301A (Zigzag)
3Ø 240 Volt
301 amps
3Ø 480 Volt
150 amps
GFCI Receptacle Load Capability
The load capability of the GFCI receptacles is directly
related to the voltage being supplied at either the output
terminals or the 2 twist lock auxiliary receptacles.
Table 9 and Table 10 show what amount of current is
available at the GFCI receptacles when the output terminals
and twist lock receptacles are in use. Be careful that your
load does not to exceed the available current capability at
the receptacles.
Figure 13. Voltage Selector Switch
Voltage Selector Switch Locking Button
To lock the voltage selector switch, press and hold the
red button located at the bottom of the switch. While
holding the red button down, insert a pad lock into the hole
next to the button to retain it in the inward locked position.
When the lock is removed, the red button is spring loaded
and will return to its normal outward unlocked position.
CAUTION
NEVER change the position of the voltage selector
switch while the engine is running. ALWAYS place
circuit breaker in the OFF position before selecting
voltage.
Table 7. Voltages Available
UVWO Output
Terminal Lugs
Voltage Selector Switch
3-Phase 240/139V Position
Voltage Selector Switch
3-Phase 480/270V Position
3Ø Line-Line
208V
220V
240V
416V
440V
480V
1Ø Line-Neutral
120V
127V
139V
240V
254V
277V
Voltage Selector Switch Single-Phase 240/120V Position
1Ø Line-Neutral/
Line-Line
120V
Line-Neutral
N/A
N/A
240V
Line-Line
N/A
N/A
Table 9. 1Ø GFCI Receptacle Load Capacity
72.0
70.8
Available Load
Current (Amps)
GFCI Duplex
5-20R 120V
0 amps/receptacle
5 amps/receptacle
69.6
10 amps/receptacle
68.4
15 amps/receptacle
67.2
20 amps/receptacle
KW in Use
Twist Lock (C6369)
1Ø 240/120V
Table 10. 3Ø GFCI Receptacle Load Capacity
KVA in Use
(UVWO Terminals)
3Ø 240/480V
Available Load
Current (Amps)
GFCI Duplex
5-20R 120V
125
0 amps/receptacle
121
5 amps/receptacle
117
10 amps/receptacle
113
15 amps/receptacle
108
20 amps/receptacle
page 26 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
GENERATOR OUTPUTS/gauge reading
how to Read the ac ammeter and ac
voltage gauges
The AC ammeter and AC voltmeter gauges are controlled
by the AC ammeter and AC voltmeter change-over switches.
Both of these switches are located on the control panel and
DO NOT effect the generator output. They are provided to
help observe how much power is being supplied, produced
at the UVWO terminals lugs.
Before taking a reading from either gauge, set the Voltage
Selector Switch (Figure 14) to the position which produces
the required voltage (For example, for 3Ø 240V, choose the
center 3Ø 240/139V position on the voltage selector switch
AC Ammeter Gauge Reading
Place the AC Ammeter Change-Over Switch (Figure 17)
in the U position and observe the current reading (load
drain) on the U terminal as indicated on the AC Ammeter
Gauge (Figure 18). This process can be repeated for
terminals V and W.
Figure 17. AC Ammeter
Change-Over Switch
Figure 18. AC Ammeter
(Amp reading on U Lug)
NOTICE
The ammeter gauge will only show a reading when
the Output Terminal Lugs are connected to a load
and in use.
Figure 14. Voltage Selector Switch240/3Ø Position
AC Voltmeter Gauge Reading
Place the AC Voltmeter Change-Over Switch (Figure 15)
in the W-U position and observe the phase to phase voltage
reading between the W and U terminals as indicated on
the AC Voltmeter Gauge (Figure 16).
Figure 15. AC Voltmeter
Change-Over Switch
Figure 16. AC Voltmeter Gauge
(Volt reading on W-U Lug)
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 27
OUTPUT TERMINAL PANEL CONNECTIONS
UVWO Terminal Output Voltages
Various output voltages can be obtained using the UVWO
output terminal lugs. The voltages at the terminals are
dependent on the position of the Voltage Selector Switch
and the adjustment of the Voltage Regulator Control
Knob.
Remember the voltage selector switch determines the
range of the output voltage. The voltage regulator (VR)
allows the user to increase or decrease the selected
voltage.
3Ø-240/139 UVWO Terminal Output Voltages
1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 19.
Figure 19. Voltage Selector Switch
3Ø-240/139V Position
2. Connect the load wires to the UVWO terminals as
shown in Figure 20.
3. Turn the voltage regulator knob (Figure 21) clockwise
to increase voltage output, turn counterclockwise to
decrease voltage output. Use voltage regulator
adjustment knob whenever fine tuning of the output
voltage is required.
Figure 21. Voltage Regulator Knob
3Ø-208V/1Ø-120V UVWO Terminal Output Voltages
1. Place the voltage selector switch in the 3Ø 240/139
position as shown in Figure 22.
Figure 22. Voltage Selector Switch
3Ø-240/139V Position
2. Connect the load wires to the UVWO terminals as
shown in Figure 23.
Figure 23. UVWO Terminal Lugs
3Ø-208/1Ø-120V Connections
NOTICE
Figure 20. UVWO Terminal Lugs
3Ø-240/139V Connections
To achieve a 3Ø 208V output the voltage selector switch
must be in the 3Ø-240/139 position and the voltage
regulator must be adjusted to 208V.
page 28 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
OUTPUT TERMINAL PANEL CONNECTIONS
3Ø-480/277V UVWO Terminal Output Voltages
1Ø-240/120V UVWO Terminal Output Voltages
1. Place the voltage selector switch in the 3Ø 480/277
position as shown in Figure 24.
1. Place the voltage selector switch in the 1Ø 240/120
position as shown in Figure 26.
Figure 24. Voltage Selector Switch
3Ø-480/277V Position
Figure 26. Voltage Selector Switch
1Ø-240/120V Position
2. Connect the load wires to the UVWO terminals as
shown in Figure 25.
2. Connect the load wires to the UVWO terminals as
shown in Figure 27.
Figure 25. UVWO Terminal Lugs
3Ø-480/277V Connections
Figure 27. UVWO Terminal Lugs
1Ø-240/120V Connections
3. Turn the voltage regulator knob (Figure 21) clockwise
to increase voltage output, turn counterclockwise
to decrease voltage output. Use voltage regulator
adjustment knob whenever fine tuning of the output
voltage is required.
3. Turn the voltage regulator knob (Figure 21) clockwise
to increase voltage output, turn counterclockwise to
decrease voltage output. Use voltage regulator
adjustment knob whenever fine tuning of the output
voltage is required.
NOTICE
ALWAYS make sure that the connections to the UVWO
terminals are secure and tight. The possibility of arcing
exists, that could cause a fire.
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 29
600 vac connections
3Ø-600V Auto-Transformer
3Ø, 600 VAC can be achieved via the auto-transformer
module. This module provides the necessary electronics
to convert the 3Ø, 480 VAC inut voltage to a 3Ø, 600 VAC
output voltage.
The 3Ø, 600 VAC ouput voltage cannot be achieved unless
the voltage selector switch (Figure 28) is placed in the 3Ø,
480/277 position.
3. After drilling, make sure all shavings and debris have
been removed from the enclosure.
4. Install customer supplied conduit, fittings and bushing
through enclosure hole opening.
5. Next, route the customer supplied 5 wires through the
straight conduit fitting.
6. Connect the 3 load wires (RED, BLACK and BLUE)
to the load side (bottom) of the circuit breaker, T1, T2
and T3 respectively. Reference Figure 30
70 AMP
CIRCUIT BREAKER
NEUTRAL BUS BAR
L2
L1
L3
Figure 28. Voltage Selector Switch
3Ø-480/277V Position (600 VAC Auto-Transformer)
T1
3Ø-600VAC Load Connections
T2
T3
DANGER
When connecting the load wires make sure the
generator is OFF. The possibility of electrocution exists
causing severe bodily harm even death!
1. Loosen the latches on the control box enclosure and
open the door.
2. Drill a 1-1/2 inch hole at the bottom of the control box
enclosure as shown in Figure 29.
BUSHING
LOCK
RING
CIRCUIT BREAKER
ENCLOSURE
GROUND
TERMINAL
LOAD
WIRES
FROM
600 VAC
AUTO
TRANSFORMER
Figure 30. Control Box Enclosure
Load Connections
DRILL
NEW HOLE
(1-1/2” DIA.)
7. Connect the neutral wire (WHITE) to the neutral bus
bar.
STRAIGHT
FITTING
8. Connect the ground wire (GREEN) to the ground
terminal.
9. Torque all wires to 45 lbf-in (5 N.m).
Figure 29. Control Box Enclosure (Drilling
10. Once all wires have been securely tighten, close
control box enclosure door and securely tighten the
control box door latches.
page 30 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
inspection/SETUP
Circuit Breakers
To protect the generator from an overload, a 3-pole, 350
amp, main circuit breaker is provided to protect the U,V,
and W Output Terminals from overload. In addition two
single-pole, 20 amp GFCI circuit breakers are provided to
protect the GFCI receptacles from overload. Three 50 amp
load circuit breakers have also been provided to protect the
auxiliary receptacles from overload. Make sure to switch
ALL circuit breakers to the OFF position prior to starting
the engine.
Lubrication Oil
Fill the engine crankcase with lubricating oil through the
filler hole, but DO NOT overfill. Make sure the generator is
level and verify that the oil level is maintained between the
two notches (Figure 31) on the dipstick. See Table 11 for
proper selection of engine oil.
Fuel Check
DANGER
Fuel spillage on a hot engine can cause
a fire or explosion. If fuel spillage occurs,
wipe up the spilled fuel completely to
prevent fire hazards. NEVER smoke
around or near the generator.
Refilling the Fuel System
CAUTION
ONLY properly trained personnel who have read
and understand this section should refill the fuel tank
system.
This generator has an internal fuel tank (Figure 32) located
inside the enclosure base and may also be equipped with
an additional trailer mounted fuel tank (option). ALWAYS
fill the fuel tanks with clean fresh #2 diesel fuel. DO NOT
fill the fuel tanks beyond their capacities.
Figure 31. Engine Oil Dipstick
When checking the engine oil, be sure to check if the oil is
clean. If the oil is not clean, drain the oil by removing the
oil drain plug, and refill with the specified amount of oil as
outlined in the ISUZU Engine Owner’s Manual. Oil should
be warm before draining.
Other types of motor oils may be substituted if they meet
the following requirements:
„„ API Service Classification CC/SC
„„API Service Classification CC/SD
„„API Service Classification CC/SE
„„API Service Classification CC/SF
Pay attention to the fuel tank capacity when replenishing
fuel. The fuel tank cap must be closed tightly after filling.
Handle fuel in a safety container. If the container does not
have a spout, use a funnel. Wipe up any spilled fuel
immediately.
Table 11. Recommended Motor Oil
Figure 32. Internal Fuel Tank System
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 31
inspection/SETUP
Refueling Procedure:
WARNING
2. Remove fuel cap (internal fuel tank) and fill tank as
shown in (Figure 34).
Diesel fuel and its vapors are dangerous
to your health and the surrounding
environment. Avoid skin contact and/or
inhaling fumes.
1. Level Tanks — Make sure fuel cells are level with the
ground. Failure to do so will cause fuel to spill from the
tank before reaching full capacity (Figure 33).
CAUTION
ALWAYS place trailer on firm level ground before
refueling to prevent spilling and maximize the amount
of fuel that can be pumped into the tank.
Figure 34. Fueling the Generator
3. NEVER overfill fuel tank — It is important to read the
fuel gauge when filling trailer fuel tank. DO NOT wait
for fuel to rise in filler neck (Figure 35).
Figure 35. Full Fuel Tank
Figure 33. Only Fill on Level Ground
NOTICE
ONLY use #2 diesel fuel when refueling.
CAUTION
DO NOT OVERFILL fuel system. Leave room for fuel
expansion. Fuel expands when heated (Figure 36).
Figure 36. Fuel Expansion
page 32 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
inspection/SETUP
Coolant (Antifreeze/Summer Coolant/
Water)
ISUZU recommends ISUZU antifreeze/summer coolant for
use in their engines, which can be purchased in concentrate
(and mixed with 50% demineralized water) or pre-diluted. See
the ISUZU Engine Owner’s Manual for further details.
Cleaning the Radiator
The engine may overheat if the radiator fins become
overloaded with dust or debris. Periodically clean the
radiator fins with compressed air. Cleaning inside the
machine is dangerous, so clean only with the engine turned
off and the negative battery terminal disconnected.
Air Cleaner
WARNING
If adding coolant/antifreeze mix to the
radiator, DO NOT remove the radiator cap
until the unit has completely cooled. The
possibility of hot! coolant exists which can
cause severe burns.
Day-to-day addition of coolant is done from the recovery
tank. When adding coolant to the radiator, DO NOT remove
the radiator cap until the unit has completely cooled. See
Table 12 for engine, radiator, and recovery tank coolant
capacities. Make sure the coolant level in the recovery tank
is always between the “H” and the “L” markings.
Periodic cleaning/replacement is necessary. Inspect it in
accordance with the ISUZU Engine Owner’s Manual.
Fan Belt Tension
A slack fan belt may contribute to overheating, or to
insufficient charging of the battery. Inspect the fan belt for
damage and wear and adjust it in accordance with the
ISUZU Engine Owner’s Manual.
The fan belt tension is proper if the fan belt bends 10 to 15
mm (Figure 37) when depressed with the thumb as shown
below.
Table 12. Coolant Capacity
Engine and Radiator
5.2 gal (19.7 liters)
Reserve Tank
TBD
Operation in Freezing Weather
When operating in freezing weather, be certain the proper
amount of antifreeze (Table 13) has been added.
Table 13. Anti-Freeze
Operating Temperatures
Freezing Point
Vol %
Anti-Freeze
°C
°F
50
-37
-34
Figure 37. Fan Belt Tension
CAUTION
NEVER place hands near the belts or fan
while the generator set is running.
NOTICE
When the antifreeze is mixed with water, the antifreeze
mixing ratio must be less than 50%.
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 33
inspection/SETUP
Battery
When connecting battery do the following:
This unit is of negative ground DO NOT connect in reverse.
Always maintain battery fluid level between the specified
marks. Battery life will be shortened, if the fluid level are
not properly maintained. Add only distilled water when
replenishment is necessary.
1. NEVER connect the battery cables to the battery
terminals when the MPEC Control Switch is in either
the MANUAL position. ALWAYS make sure that the
MPEC Control Switch is in the OFF/RESET position
when connecting the battery.
DO NOT over fill. Check to see whether the battery
cables are loose. Poor contact may result in poor starting
or malfunctions. Always keep the terminals firmly
tightened. Coating the terminals with an approved battery
terminal treatment compound. Replace battery with only
recommended type battery.
2. Place a small amount of battery terminal treatment
compound around both battery terminals. This will
ensure a good connection and will help prevent
corrosion around the battery terminals.
The battery is sufficiently charged if the specific gravity
of the battery fluid is 1.28 (at 68° F). If the specific gravity
should fall to 1.245 or lower, it indicates that the battery is
dead and needs to be recharged or replaced.
Before charging the battery with an external electric source,
be sure to disconnect the battery cables.
Battery Cable Installation
ALWAYS be sure the battery cables (Figure 38) are
properly connected to the battery terminals as shown below.
The red cable is connected to the positive terminal of the
battery, and the black cable is connected to the negative
terminal of the battery.
CAUTION
ALWAYS disconnect the negative terminal FIRST and
reconnect negative terminal LAST.
NEGATIVE
POSITIVE
NOTICE
If the battery cable is connected incorrectly, electrical
damage to the generator will occur. Pay close attention
to the polarity of the battery when connecting the battery.
CAUTION
Inadequate battery connections may cause poor
starting of the generator, and create other malfunctions.
Alternator
The polarity of the alternator is negative grounding type.
When an inverted circuit connection takes place, the
circuit will be in short circuit instantaneously resulting the
alternator failure.
DO NOT put water directly on the alternator. Entry of water
into the alternator can cause corrosion and damage the
alternator.
Wiring
Inspect the entire generator for bad or worn electrical wiring
or connections. If any wiring or connections are exposed
(insulation missing) replace wiring immediately.
Piping and Hose Connection
Inspect all piping, oil hose, and fuel hose connections for
wear and tightness. Tighten all hose clamps and check
hoses for leaks.
Figure 38. Battery Connections
If any hose (fuel or oil) lines are defective replace them
immediately.
page 34 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
GENERATOR START-UP PROCEDURE
Before Starting
Starting
CAUTION
The engine’s exhaust contains harmful emissions.
ALWAYS have adequate ventilation when operating.
Direct exhaust away from nearby personnel.
1. Place the voltage selector switch in the desired
voltage position (Figure 41)..
WARNING
NEVER manually start the engine with the main, GFCI
or auxiliary circuit breakers in the ON (closed) position.
1. Place the main, G.F.C.I., and aux. circuit breakers
(Figure 39) in the OFF position prior to starting the
engine.
Figure 41. Voltage Selector Switch
Starting (Manual)
1. Place the engine speed switch (Figure 42) in the LOW
(down) position.
Figure 39. Main, Aux. and GFCI
Circuit Breakers (OFF)
2. Make sure the voltage change-over board has been
configured for the desired output voltage.
3. Connect the load to the receptacles or the output
terminal lugs as shown in Figure 10. These load
connection points can be found on the output terminal
panel and the output terminal panel’s hard wire hookup
panel.
4. Tighten terminal nuts securely to prevent load wires
from slipping out.
Figure 42. Engine Speed Switch (Low)
2. Located in the control box is the engine controller
diagnostic switch (Figure 43). Verify that this switch
has been placed in the OFF position (down).
Figure 43. Diagnostic Switch
3. Place the MPEC control switch in the MANUAL
position to start the engine (Figure 44).
5. Close all engine enclosure doors (Figure 40).
Figure 44. MPEC Control Switch
(Manual Position)
CORRECT
INCORRECT
Figure 40. Engine Enclosure Doors
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 35
GENERATOR START-UP PROCEDURE
4. Depending on the temperature of the coolant (cold
weather conditions), the pre-heat lamp (Figure 45) will
light (ON) and remain on until the pre-heating cycle has
been completed. After completion of the pre-heating
cycle, the light will go OFF and the engine will start up
automatically.
8. The generator’s AC-voltmeter (Figure 49) will display
the generator’s output in VOLTS.
Figure 49. Voltmeter
Figure 45. Pre-Heat Lamp
5. Once the engine starts, let the engine run for 1-2
minutes. Listen for any abnormal noises. If any
abnormalities exist, shut down the engine and correct
the problem. If the engine is running smoothly, place
the engine speed switch (Figure 46) in the HIGH (up)
position.
9. If the voltage is not within the specified tolerance, use
the voltage adjustment control knob (Figure 50) to
increase or decrease the desired voltage.
Figure 50. Voltage Adjust Control Knob
Figure 46. Engine Speed Switch (High)
6. Verify that the Engine Running status LED on the
MPEC unit (Figure 47) in ON (lit) after the engine has
been started
10. The ammeter (Figure 51) will indicate zero amps with
no load applied. When a load is applied, the ammeter
will indicate the amount of current that the load is
drawing from the generator.
Figure 51. Ammeter (No Load)
Figure 47. Engine Running LED (ON)
7. The generator’s frequency meter (Figure 48) should be
displaying the 60 cycle output frequency in HERTZ.
11. The engine oil pressure gauge (Figure 52) will indicate
the oil pressure of the engine. Under normal operating
conditions the oil pressure is approximately 42 to 71
psi. (290~490 kPa).
Figure 52. Oil Pressure Gauge
Figure 48. Frequency Meter
page 36 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
GENERATOR SHUT-DOWN PROCEDURES
12. The coolant temperature gauge (Figure 53) will
indicate the coolant temperature. Under normal
operating conditions the coolant temperature should
be between 167°~203°F (75°~95°C) (Green Zone).
WARNING
NEVER stop the engine suddenly except in an
emergency.
Normal Shutdown Procedure
To shutdown the generator, use the following procedure:
Figure 53. Coolant Temperature Gauge
1. Place both the MAIN, GFCI and LOAD circuit breakers
as shown in Figure 57 to the OFF position..
13. The tachometer gauge (Figure 54) will indicate the
speed of the engine when the generator is operating.
Under normal operating conditions this speed is
approximately 1800 RPM’s.
Figure 57. Main, GFCI and Load
Circuit Breakers Off
Figure 54. Engine Tachometer Gauge
2. Place the engine speed switch (Figure 58) in the “LOW”
(down) position..
14. Place the main, GFCI, and aux. circuit breakers in the
ON position (Figure 55).
Figure 58. Ignition Switch (Normal)
3. Let the engine cool by running it at low speed for 3-5
minutes with no load applied.
4. Place the MPEC Control Switch (Figure 59) to the
OFF/RESET position.
Figure 55. Main, Aux. and GFCI
Circuit Breakers (ON)
15. Observe the generator’s ammeter (Figure 56) and
verify it reads the anticipated amount of current with
respect to the load. The ammeter will only display a
current reading if a load is in use.
Figure 59. MPEC Control Switch (Off/Reset)
5. Verify that all status LEDs on the MPEC display are
OFF (not lit).
6. Remove all loads from the generator.
7. Inspect entire generator for any damage or loosening of
components that may have occurred during operation.
Figure 56. Ammeter (Load)
Emergency Shutdown Procedure
16. The generator will run until manually stopped or an 1. Place the MPEC Control Switch (Figure 59) in the
abnormal condition occurs.
OFF/RESET position.
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 37
Maintenance
10 Hrs
DAILY
X
X
X
X
X
X
Table 14. Inspection/Maintenance
Engine
Generator
Check Engine Fluid Levels
Check Air Cleaner
Check Battery Acid Level
Check Fan Belt Condition
Check for Leaks
Check for Loosening of Parts
Replace Engine Oil and Filter * 1
Clean Air Filter
Check Fuel Filter/Water Separator Bowl
Clean Unit, Inside and Outside
Change Fuel Filter
Clean Radiator and Check Coolant Protection Level*2
Replace Air Filter Element * 3
Check all Hoses and Clamps * 4
Clean Inside of Fuel Tank
Measure Insulation Resistance Over 3M ohms
Check Rotor Rear Support Bearing
250 Hrs
500 Hrs
1000
Hrs
X
X
X
X
X
X
X
X
X
X
X
*1 Replace engine oil and filter at 100 hours, first time only.
*2 Add “Supplemental Coolant Additives (SCA’S)” to recharge the engine coolant.
*3 Replace primary air filter element when restriction indicator shows a vacuum of 625 mm (25 in. H20).
*4 If blowby hose needs to be replaced, ensure that the slope of the blowby hose is at least a 1/2 inch per foot,
with no sags or dips that could collect moisture and/or oil.
General Inspection
Prior to each use, the generator should be cleaned and
inspected for deficiencies. Check for loose, missing or
damaged nuts, bolts or other fasteners. Also check for
fuel, oil, and coolant leaks. Use Table 14 as a general
maintenance guideline. Engine Side, refer to the Engine
Instruction Manual.
Air Cleaner
Every 250 hours: Remove air cleaner element (Figure 60)
and clean the heavy duty paper element with light spray of
compressed air. Replace the air cleaner as needed.
Air Cleaner with Dust Indicator
This indicator (Figure 60) is attached to the air cleaner.
When the air cleaner element is clogged, air intake
restriction becomes greater and the dust indicator signal
shows RED meaning the element needs changing or
service. After changing the air element, press the dust
indicator button to reset the indicator.
Figure 60. Air Cleaner/Indicator
NOTICE
The air filter should not be changed until the indicator
reads “RED”. Dispose of old air filter. It may not be
cleaned or reused.
page 38 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
Maintenance
If the engine is operating in very dusty or dry grass
conditions, a clogged air cleaner will result. This can lead to
a loss of power, excessive carbon buildup in the combustion
chamber and high fuel consumption. Change air cleaner
more frequently if these conditions exists.
Fuel Addition
Add diesel fuel (the grade may vary according to season
and locations).
Removing Water from the Fuel Tank
After prolonged use, water and other impurities accumulate
in the bottom of the tank. Occasionally inspect the fuel tank
for water contamination and drain the contents if required.
During cold weather, the more empty volume inside the
tank, the easier it is for water to condense. This can be
reduced by keeping the tank full with diesel fuel.
Cleaning Inside the Fuel Tank
If necessary, drain the fuel inside the fuel tank completely.
Using a spray washer (Figure 61) wash out any deposits
or debris that have accumulated inside the fuel tank.
Fuel Tank Inspection
In addition to cleaning the fuel tank, the following
components should be inspected for wear:
„„Rubber Suspension — look for signs of wear or
deformity due to contact with oil. Replace the rubber
suspension if necessary.
„„Fuel Hoses — inspect nylon and rubber hoses for signs
of wear, deterioration and hardening.
„„Fuel Tank Lining — inspect the fuel tank lining for signs
of excessive amounts of oil or other foreign matter.
Replacing Fuel Filter
„„Replace the fuel filter cartridge with new one every 500
hours or so.
„„Loosen the drain plug at the lower top of the fuel filter.
Drain the fuel in the fuel body together with the mixed
water. DO NOT spill the fuel during disassembly.
„„Vent any air
Air Removal
If air enters the fuel injection system of a diesel engine,
starting becomes impossible. After running out of fuel,
or after disassembling the fuel system, bleed the system
according to the following procedure. See the ISUZU
Engine Manual for details.
To restart after running out of fuel, turn the switch to the
“ON” position for 15-30 seconds. Try again, if needed.
Figure 61. Fuel Tank Cleaning
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 39
Maintenance
Check Oil Level
Radiator Cleaning
Check the crankcase oil level prior to each use, or when the
fuel tank is filled. Insufficient oil may cause severe damage
to the engine. Make sure the generator is level. The oil
level must be between the two notches on the dipstick as
shown in Figure 31.
The radiator (Figure 62) should be sprayed (cleaned) with
a high pressure washer when excessive amounts of dirt
and debris have accumulated on the cooling fins or tube.
When using a high pressure washer, stand at least 5 feet
(1.5 meters) away from the radiator to prevent damage to
the fins and tube.
Replacing Oil Filter
„„Remove the old oil filter.
„„Apply a film of oil to the gasket on the new oil filter.
„„Install the new oil filter.
„„After the oil cartridge has been replaced, the engine oil
will drop slightly. Run the engine for a while and check for
leaks before adding more oil if needed. Clean excessive
oil from engine.
Flushing Out Radiator and Replacing
Coolant
„„Open both cocks located at the crankcase side and at
the lower part of the radiator and drain coolant. Open
the radiator cap while draining. Remove the overflow
tank and drain.
„„Check hoses for softening and kinks. Check clamps for
signs of leakage.
Figure 62. Radiator Cleaning
Generator Storage
For long term storage of the generator the following is
recommended:
„„Tighten both cocks and replace the overflow tank.
„„Drain the fuel tank completely. Treat with a fuel stabilizer
if necessary.
„„Replace with coolant as recommended by the engine
manufacturer.
„„Completely drain the oil from the crankcase and refill if
necessary with fresh oil.
„„Close radiator cap tightly.
„„Clean the entire generator, internal and external.
„„Flush the radiator by running clean tap water through
radiator until signs of rust and dirt are removed. DO
NOT clean radiator core with any objects, such as a
screwdriver.
„„Cover the generating set and store in a clean, dry place.
WARNING
Allow engine to cool when flushing out
radiator. Flushing the radiator while hot
could cause serious burns from water or
steam.
„„Disconnect the battery.
„„Make sure engine coolant is at proper level.
„„If generator is mounted on a trailer, jack trailer up and
place on blocks so tires do not touch the ground or block
and completely remove the tires.
page 40 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
Maintenance
Jacket Water Heater and Internal Battery
Charger 120 VAC Input Receptacles
(OPTIONAL)
This generator can be optionally equipped with two 120
VAC, 20 amp input receptacles located on the output
terminal panel.
The purpose of these receptacles is to provide power via
commercial power to the jacket water heater and internal
battery charger.
These receptacles will ONLY function when commercial
power has been supplied to them (Figure 63). To apply
commercial power to these receptacles, a power cord of
adequate size will be required (See Table 6).
When using the generator in hot climates there is no reason
to apply power to jacket water heater. However, if the
generator will be used in cold climates it is always a good
idea to apply power to the jacket water heater at all times. To
apply power to the jacket water heater simply apply power
to the jacket water heater receptacle via commercial power
using an power cord of adequate size.
If the generator will be used daily, the battery should
normally not require charging. If the generator will be idle
(not used) for long periods of time, apply power to the
battery charger receptacle via commercial power using an
power cord of adequate size.
NOTICE
To ensure adequate starting capability, always have
power applied to the generator's internal battery
charger..
OUTPUT TERMINAL
PANEL ASSEMBLY
REFERENCE TABLE 7
FOR PROPER SIZE
EXTENSION CORD
BATTERY CHARGER
JACKET WATER HEATER
120 VAC INPUT
RECEPTACLE
CONNECT TO
EXTERNAL
120 VAC POWER
SOURCE
Figure 63. Battery Charger & Jacket Water Heater Power Connections
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 41
Trailer Maintenance
The following trailer maintenance guidelines are intended
to assist the operator in preventive maintenance.
Trailer Brakes
6. Replace the adjusting-hole cover.
7. Repeat the above procedure on all brakes.
8. Lower the trailer to the ground.
Properly functioning brake shoes and drums are essential
to ensure safety. The brakes should be inspected the first
200 miles of operation. This will allow the brake shoes and
drums to seat properly. After the first 200 mile interval,
inspect the brakes every 3,000 miles. If driving over rough
terrain, inspect the brakes more frequently.
Check the fluid level in the master cylinder reservoir at least
every three months. If you tow your trailer an average of
1,000 miles per month in a hot and dry environment, you
must check the brake fluid level once a month. The brake
fluid reservoir is located on the tongue of the trailer. Always
fill with clean, uncontaminated DOT 4 brake fluid.
hydraulic Brakes
Figure 64 below displays the major hydraulic brake
components that will require inspection and maintenance.
Please inspect these components as required using steps
1 through 6 as referenced in the “Manually Adjusting The
Brakes” section on this page. See Table 1 for Hydraulic
Brake Troubleshooting.
If your trailer has hydraulic brakes, they function the same
way the surge brakes do on your tow vehicle. The hydraulic
braking system must be inspected at least as often as the
brakes on the tow vehicle, but no less than once per year.
This inspection includes an assessment of the condition
and proper operation of the wheel cylinders, brake shoes,
brake drums and hubs.
Manually Adjusting the Brakes
Most axles are fitted with a brake mechanism that will adjust
the brakes during a hard stop. However, some braking
systems are not automatically adjusted by hard stopping.
These brakes require manual adjustment. The following
steps apply to adjust most manually adjustable brakes.
1. Jack up the trailer and secure it on adequate capacity
jackstands.
2. Be sure the wheel and brake drum rotate freely.
3. Remove the adjusting-hole cover from the adjusting
slot on the bottom of the brake backing plate.
4. With a screwdriver or standard adjusting tool, rotate the
starwheel of the adjuster assembly to expand the brake
shoes. Adjust the brake shoes out until the pressure
of the linings against the drum makes the wheel very
difficult to turn. Note: Your trailer maybe equipped with
drop spindle axles. See axle manual for your axle type.
You will need a modified adjusting tool for adjusting
the brakes in these axles. With drop spindle axles, a
modified adjusting tool with about an 80 degree angle
should be used.
Figure 64. Hydraulic Brake Components
Hydraulic Brake Actuator
The hydraulic brake actuator (Figure 65) is the mechanism
that activates the trailer’s brake system. This actuator
changes fluid power into mechanical power. Therefore, the
fluid level must be checked frequently to assure that the
brakes function properly.
HYDRAULIC
BRAKE FLUID
RESERVOIR
5. Rotate the starwheel in the opposite direction until the
wheel turns freely with a slight drag.
Figure 65. Hydraulic Brake Actuator
page 42 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
Trailer Maintenance
ADJUSTABLE
CHANNEL
WARNING
Failure to maintain proper fluid level in the actuator
may result in loss of braking action which could cause
severe property damage, injury or death.
Periodically check the actuator mounting fasteners for
damage or loosening. Inspect the actuator for worn or
damaged parts. As you are towing your trailer, be aware
of any changes in braking quality. This could be an early
warning of brake or actuator malfunction and requires
immediate attention. Consult a certified brake specialist to
make necessary adjustment or repairs.
Table 15. Hydraulic Brake Troubleshooting
Symptom
Possible Cause
Solution
No Brakes
Brake line broken or kinked?
Repair or replace.
Brake lining glazed?
Reburnish or replace.
Trailer overloaded?
Correct weight.
Brake drums scored or
grooved?
Machine or replace.
Weak Brakes or
Brakes Pull to
One Side
Locking Brakes
Noisy Brakes
Dragging
Brakes
Tire pressure correct?
Inflate all tires equally.
Tires unmatched on the
same axle?
Match tires.
Brake components loose,
bent or broken?
Replace components.
Brake drums out-of-round?
Replace.
System lubricated?
Lubricate.
Brake components correct?
Replace and correct.
Brake lining thickness
incorrect or not adjusted
correctly?
Install new shoes and
linings.
Enough brake fluid or correct
fluid?
Replace rubber parts
fill with dot 4 fluid.
Adjustable Channel
Your trailer may be equipped with an adjustable channel
(Figure 66) that allows the coupler to be raised or lowered
to a desired height. Periodically check the channel bolts
for damage or loosening.
NOTICE
When replacing channel mounting hardware (nuts,
bolts and washers), NEVER substitute substandard
hardware. Pay close attention to bolt length and grade.
ALWAYS use manufacturer's recommended parts
when replacing channel mounting hardware.
5/8" X 11" X 5"
BOLT
2" or 2-5/16" BALL
COUPLER
ADJUSTABLE
CHANNEL
5/8"
NYLOC
5/8" FLAT
NUT
WASHER
5/8" X 11" X 5"
BOLT
3" PINTLE EYE
RING
5/8" FLAT
WASHER
5/8"
NYLOC
NUT
Figure 66. Adjustable Channel
Wheel Bearings
Wheel bearings (Figure 67) must be inspected and
lubricated once a year or 12,000 miles to insure safe
operation of your trailer.
If trailer wheel bearings are immersed in water, they must
be replaced.
DANGER
If trailer wheels are under water for a long period of
time, wheel bearings may fail. If this is the case, service
wheel bearings immediately.
The possibility exists of the wheels falling off causing
equipment damage and severe bodily harm even death!
If the trailer has not been used for an extended amount
of time, have the bearings inspected and packed more
frequently, at least every six months and prior to use.
Follow the steps below to disassemble the wheel hub and
service the wheel bearings. See Figure 67.
BEARING
WHEEL
HUB
OIL
SEAL
BEARING COTTER
PIN
CUP
BEARING
BEARING
CUP
DUST
CAP
LUG
NUT
SPINDLE
WASHER
SPINDLE
NUT
Figure 67. Wheel Hub Components
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 43
Trailer Maintenance
„„After removing the dust cap, cotter pin, spindle nut and
spindle washer, remove the hub to inspect the bearings
for wear and damage.
„„Replace bearings that have flat spots on rollers, broken
roller cages, rust or pitting. Always replace bearings
and cups in sets. The inner and outer bearings are to
be replaced at the same time.
DANGER
Improper weld repair will lead to early failure of the
trailer structure and can cause serious injury or death.
DO NOT repair cracked or broken welds unless you
have a certified welder perform the repair. If not, have
the welds repaired by your dealer.
„„Replace seals that have nicks, tears or wear.
„„Lubricate the bearings with a high quality EP-2
automotive wheel bearing grease.
Wheel Hub Adjustment
Every time the wheel hub is removed and the bearings are
reassembled, follow the steps below to check the wheel
bearings for free running and adjust.
„„Turn the hub slowly, by hand, while tightening the spindle
nut until you can no longer turn the hub by hand.
„„Loosen the spindle nut just until you are able to turn it
(the spindle nut) by hand. Do not turn the hub while the
spindle nut is loose.
WARNING
If the trailer is involved in an accident, have it inspected
immediately by qualified personnel. In addition, the
trailer should be inspected annually for signs of wear
or deformations.
Leaf Suspension
The leaf suspension springs and associated components
(Figure 68) should be visually inspected every 6,000
miles for signs of excessive wear, elongation of bolt holes,
and loosening of fasteners. Replace all damaged parts
(suspension) immediately.
SHACKLE SUPPORT
IS WELDED
HANGER SUPPORT
TO FRAME
IS WELDED
TO FRAME
HANGER
SUPPORT
SHACKLE
NUT
NUT
„„Install a new cotter pin through the spindle nut and axle.
„„Check the adjustments. Both the hub and the spindle nut
should be able to move freely (the spindle nut motion
will be limited by the cotter pin).
DANGER
NEVER crawl under the trailer unless it is on firm
and level ground and resting on properly placed and
secured jackstands.
The possibility exists of the trailer falling thus causing
equipment damage and severe bodily harm even death!
DANGER
HANGER
SUPPORT
BOLT
TIE
PLATE
AXLE
SHACKLE
BOLT
U-BOLT
LOCKING
NUT
Figure 68. Leaf Suspension Components
DANGER
When performing trailer inspection and maintenance
activities, you must jack up the trailer using jacks and
jackstands.
Worn or broken suspension parts can cause loss of
control, damage to equipment and severe bodily injury,
even death!
When jacking and using jackstands, place them so
as to clear wiring, brake lines, and suspension parts
(i.e., springs, torsion bars). Place jacks and jackstands
inside of the perimeter strip on the supporting structure
to which the axles are attached.
Check suspension regularly.
page 44 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
Trailer guidelines
The following guidelines are intended to assist the operator
in the operation and handling of a trailer.
„ Shift your automatic transmission into a lower gear for
city driving.
Safety precautions should be followed at all times when
operating a trailer. Failure to read, understand and follow
the safety guidelines could result in injury to yourself and
others. Loss of control of the trailer or tow vehicle can result
in death or serious injury.
„ alWaYS use lower gears for climbing and descending
grades.
CommoN CaUSeS For loSS oF traIler
„ Driving too fast for the conditions (maximum speed when
towing a trailer is 55 mph).
„ Overloading the trailer or loading the trailer unevenly.
„ Trailer improperly coupled to the hitch.
„ No braking on trailer.
„ Not maintaining proper tire pressure.
„ Not keeping lug nuts tight.
„ Not properly maintaining the trailer structure.
„ Ensure machine is towed level to tow vehicle.
traIler toWINg gUIDelINeS
„ Recheck the load tiedowns to make sure the load will
not shift during towing.
„ Before towing, check coupling, safety chain, safety
brake, tires, wheels and lights.
„ Check the lug nuts or bolts for tightness.
„ Check coupler tightness after towing 50 miles.
„ Use your mirrors to verify that you have room to change
lanes or pull into traffic.
„ Use your turn signals well in advance. Allow plenty of
stopping space for your trailer and tow vehicle.
„ Allow plenty of stopping space for your trailer and tow
vehicle.
„ DO NOT drive so fast that the trailer begins to sway
due to speed.
„ Allow plenty of room for passing. A rule of thumb is that
the passing distance with a trailer is 4 times the passing
distance without the trailer.
„ DO NOT ride the brakes while descending grades, they
may get so hot that they stop working. Then you will
potentially have a runaway tow vehicle and trailer.
„ To conserve fuel, don’t use full throttle to climb a hill.
Instead, build speed on the approach.
„ Slow down for bumps in the road. Take your foot off the
brake when crossing the bump.
„ DO NOT brake while in a curve unless absolutely
necessary. Instead, slow down before you enter the
curve and power through the curve. This way, the towing
vehicle remains in charge.
„ DO NOT apply the brakes to correct extreme trailer
swaying. Continued pulling of the trailer, and even slight
acceleration, will provide a stabilizing force.
„ Anticipate the trailer “swaying.” Swaying is the trailer
reaction to the air pressure wave caused by passing
trucks and buses. Continued pulling of the trailer provides
a stabilizing force to correct swaying. DO NOT apply the
brakes to correct trailer swaying.
„ Use lower gear when driving down steep or long grades.
Use the engine and transmission as a brake. Do not
ride the brakes, as they can overheat and become
ineffective.
„ Be aware of your trailer height, especially when
approaching roofed areas and around trees.
„ Make regular stops, about once each hour. Confirm
that:
•Coupler is secure to the hitch and is locked.
•Electrical connectors are secure.
•There is appropriate slack in the safety chains.
•There is appropriate slack in the breakaway switch
pullpin cable.
•Tires are not visibly low on pressure.
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 45
Trailer guidelines
DrIvINg CoNDItIoNS
When towing a trailer, you will have decreased acceleration,
increased stopping distance, and increased turning radius
(which means you must make wider turns to keep from
hitting curbs, vehicles, and anything else that is on the
inside corner). In addition, you will need a longer distance
to pass, due to slower acceleration and increased length.
„ Be alert for slippery conditions. You are more likely to be
affected by slippery road surfaces when driving a tow
vehicle with a trailer, than driving a tow vehicle without
a trailer.
„ Check rearview mirrors frequently to observe the trailer
and traffic.
„ Never drive faster than what is safe.
WARNING
Driving too fast for severe road conditions can result in
loss of control and cause death or serious injury.
Decrease your speed as road, weather, and lighting
conditions deteriorate.
Always check for local trailer tow speed limits in your
area.
WARNING
Do not transport people on the trailer. The transport of
people puts their lives at risk and may be illegal.
CoUplINg to the toW vehICle
Follow all of the safety precautions and instructions in
this manual to ensure safety of persons, equipment, and
satisfactory life of the trailer. Always use an adequate tow
vehicle and hitch. If the vehicle or hitch is not properly
selected and matched to the Gross Vehicle Weight Rating
(GVWR) of your trailer, you can cause an accident that
could lead to death or serious injury.
If you already have a tow vehicle, know your vehicle tow
rating and make certain the trailer’s rated capacity is less
than or equal to the tow vehicle’s rated towing capacity. If
you already have (or plan to buy) a trailer, make certain
that the tow rating of the tow vehicle is equal to or greater
than that of the trailer.
The trailer VIN tag contains the critical safetyinformation
for the use of your trailer. Again, be sure your hitch and tow
vehicle are rated for the Gross Vehicle Weight Rating of
your trailer.
WARNING
Proper selection and condition of the coupler and hitch
are essential to safely towing your trailer. A loss of
coupling may result in death or serious injury.
• Be sure the hitch load rating is equal to or greater
than the load rating of the coupler.
• Be sure the hitch size matches the coupler size.
• Observe the hitch for wear, corrosion and cracks
before coupling. Replace worn, corroded or cracked
hitch components before coupling the trailer to the
tow vehicle.
• Be sure the hitch components are tight before
coupling the trailer to the tow vehicle.
WARNING
An improperly coupled trailer can result in death or
serious injury.
DO NOT move the trailer until:
• The coupler is secured and locked to hitch.
• The safety chains are secured to the tow vehicle.
• The trailer jack(s) are fully retracted.
DO NOT tow the trailer on the road until:
• Tires and wheels are checked.
• The trailer brakes are checked.
• The breakaway switch is connected to the tow
vehicle.
• The load is secured to the trailer.
• The trailer lights are connected and checked.
WARNING
Use of a hitch with a load rating less than the load rating
of the trailer can result in loss of control and may lead
to death or serious injury.
Use of a tow vehicle with a towing capacity less than
the load rating of the trailer can result in loss of control,
and may lead to death or serious injury.
Be sure your hitch and tow vehicle are rated for the
Gross Vehicle Weight Rating of your trailer.
page 46 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
Trailer guidelines
INoperaBle BraKeS, lIghtS or mIrrorS
Be sure that the brakes and all of the lights on your trailer
are functioning properly before towing your trailer. Check
the trailer taillights by turning on your tow vehicle headlights.
Check the trailer brake lights by having someone step on
the tow vehicle brake pedal while you look at trailer lights.
Do the same thing to check the turn signal lights. See Trailer
Wiring Diagram section in this manual.
Standard mirrors usually do not provide adequate visibility
for viewing traffic to the sides and rear of a towed trailer.
You must provide mirrors that allow you to safely observe
approaching traffic.
WARNING
Improper electrical connection between the tow vehicle
and the trailer will result in inoperable lights and can
lead to collision.
Before each tow, check that the tail lights, brake lights
and turn signals work.
traIler toWINg tIpS
Driving a vehicle with a trailer in tow is vastly different
from driving the same vehicle without a trailer in tow.
Acceleration, maneuverability and braking are all diminished
with a trailer in tow.
It takes longer to get up to speed, you need more room to
turn and pass, and more distance to stop when towing a
trailer. You will need to spend time adjusting to the different
feel and maneuverability of the tow vehicle with a loaded
trailer.
Because of the significant differences in all aspects of
maneuverability when towing a trailer, the hazards and risks
of injury are also much greater than when driving without
a trailer. You are responsible for keeping your vehicle and
trailer in control, and for all the damage that is caused if
you lose control of your vehicle and trailer.
As you did when learning to drive an automobile, find
an open area with little or no traffic for your first practice
trailering. Of course, before you start towing the trailer, you
must follow all of the instructions for inspection, testing,
loading and coupling. Also, before you start towing, adjust
the mirrors so you can see the trailer as well as the area
to the rear of it.
Drive slowly at first, 5 mph or so, and turn the wheel to
get the feel of how the tow vehicle and trailer combination
responds. Next, make some right and left hand turns.
Watch in your side mirrors to see how the trailer follows
the tow vehicle. Turning with a trailer attached requires
more room.
Stop the rig a few times from speeds no greater than
10 mph. If your trailer is equipped with brakes, try using
different combinations of trailer brake and tow vehicle brake.
Note the effect that the trailer brakes have when they are
the only brakes used. When properly adjusted, the trailer
brakes will come on just before the tow vehicle brakes.
It will take practice to learn how to back up a tow vehicle
with a trailer attached. Take it slow. Before backing up, get
out of the tow vehicle and look behind the trailer to make
sure that there are no obstacles.
Some drivers place their hands at the bottom of the steering
wheel, and while the tow vehicle is in reverse, “think” of the
hands as being on the top of the wheel. When the hands
move to the right (counterclockwise, as you would do to
turn the tow vehicle to the left when moving forward), the
rear of the trailer moves to the right. Conversely, rotating
the steering wheel clockwise with your hands at the bottom
of the wheel will move the rear of the trailer to the left while
backing up.
If you are towing a bumper hitch rig, be careful not to allow
the trailer to turn too much because it will hit the rear of the
tow vehicle. To straighten the rig, either pull forward or turn
the steering wheel in the opposite direction.
traIler vIN tag
Figure A below is a sample of the Vehicle Identification
Number (VIN) Tag which is typically located on the left front
of the trailer. See Figure B for location.
Figure A. Vehicle VIN Tag
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 47
Trailer guidelines
VI
N
TA
G
VIN TAG
Figure B. Typical VIN Tag Location
To determine the “empty” or “net” weight of your trailer,
weigh it on an axle scale. To find the weight of the trailer
using an axle scale, you must know the axle weights of
your tow vehicle without the trailer coupled. Some of the
trailer weight will be transferred from the trailer to the tow
vehicle axles, and an axle scale weighs all axles, including
the tow vehicle axles.
toW vehICle
The towing hitch attached to your tow vehicle must have a
capacity equal to or greater than the load rating of the trailer
you intend to tow. The hitch capacity must also be matched
to the tow vehicle capacity. Your vehicle dealer can provide
and install the proper hitch on your tow vehicle.
The trailer VIN Tag contains the following critical safety
information for the use of your trailer.
SUSpeNSIoN SYStem
GAWR: The maximum gross weight that an axle cansupport.
It is the lowest of axle, wheel, or tire rating.
Sway bars, shock absorbers, heavy duty springs, heavy
duty tires and other suspension components may be
required to sufficiently tow the trailer and pump.
Usually, the tire or wheel rating is lower than the axle rating,
and determines GAWR.
gvWr: The maximum allowable gross weight of the trailer
and its contents. The gross weight of the trailer includes
the weight of the trailer and all of the items within it. GVWR
is sometimes referred to as GTWR (Gross Trailer Weight
Rating), or MGTW (Maximum Gross Trailer Weight). GVWR,
GTWR and MGTW are all the same rating.
The sum total of the GAWR for all trailer axles may be less
than the GVWR for the trailer, because some of the trailer
load is to be carried by the tow vehicle, rather than by the
trailer axle(s). The total weight of the cargo and trailer must
not exceed the GVWR, and the load on an axle must not
exceed its GAWR.
BraKe CoNtroller
For trailers equipped with electric brakes, the electric brake
controller is part of the tow vehicle and is essential in the
operation of the electric brakes on the trailer. The brake
controller is not the same as the safety breakaway brake
system that may be equipped on the trailer.
SIDe vIeW mIrrorS
PSIC: The tire pressure (psi) measured when cold.
The size of the trailer that is being towed and your state
law regulations determine the size of the mirrors. However,
some states prohibit extended mirrors on a tow vehicle,
except while a trailer is actually being towed. In this
situation, detachable extended mirrors are necessary.
Check with your dealer or the appropriate state agency
for mirror requirements.
vIN: The Vehicle Identification Number.
heavY DUtY FlaSher
emptY WeIght: Some information that comes with the
trailer (such as the Manufacturer’s Statement of Origin)
is not a reliable source for “empty” or “net” weight. The
shipping documents list average or standard weights and
your trailer may be equipped with options.
A Heavy Duty Flasher is an electrical component that may
be required when your trailer turn signal lights are attached
to the tow vehicle flasher circuit.
eleCtrICal CoNNeCtor
An Electrical Connector connects the light and brake
systems on the trailer to the light and brake controls on
the towing vehicle.
page 48 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
Trailer guidelines
emergeNCY FlareS aND trIaNgle reFleCtorS
Ball hItCh CoUpler
It is wise to carry these warning devices even if you are
not towing a trailer. It is particularly important to have these
when towing a trailer because the hazard flashers of your
towing vehicle will not operate for as long a period of time
when the battery is running both the trailer lights and tow
vehicle lights.
A ball hitch coupler (Figure C) connects to a ball that is
located on or under the rear bumper of tow vehicle. This
system of coupling a trailer to a tow vehicle is sometimes
referred to as “bumper pull.”
SAFETY CHAINS
If the coupler connection comes loose, the safety chains
can keep the trailer attached to the tow vehicle. With
properly rigged safety chains, it is possible to keep the
tongue of the trailer from digging into the road pavement,
even if the coupler-to-hitch connection comes apart.
A ball hitch trailer may be fitted with a tongue jack that can
raise and lower the coupler. The tongue jack is mounted to
the A-frame (front or tongue) part of the trailer. By rotating
the jack handle clockwise, the jack will extend and raise
the tongue of the trailer.
traIler lIghtINg aND BraKINg CoNNeCtor
A device that connects electrical power from the tow vehicle
to the trailer. Electricity is used to turn on brake lights,
running lights, and turn signals as required. In addition, if
your trailer has a separate braking system, the electrical
connector will also supply power to the brakes from the
tow vehicle.
BreaKaWaY SYStem
If the trailer coupler connection comes loose, the breakaway
system can actuate emergency hydraulic brakes depending
on the type of actuator on the trailer. The breakaway cable
must be rigged to the tow vehicle with appropriate slack
that will activate the system if the coupler connection
comes loose.
JACKSTAND
A device on the trailer that is used to raise and lower the
coupler. The jack is sometimes called the “landing gear” or
the “tongue jack”.
CoUpler tYpeS
Two types of coupler used wit the trailer are discussed
below.
„ Ball Hitch Coupler
„ Pintel Eye Coupler
Figure C. Ball Hitch Coupler
Before each tow, coat the ball with a thin layer of automotive
bearing grease to reduce wear and ensure proper operation.
Check the locking device that secures the coupler to the
ball for proper operation.
If you see or feel evidence of wear, such as flat spots,
deformations, pitting or corrosion, on the ball or coupler,
immediately have your dealer inspect them to determine
the proper action to prevent possible failure of the ball and
coupler system. All bent or broken coupler parts must be
replaced before towing the trailer.
The coupler handle lever must be able to rotate freely and
automatically snap into the latched position. Oil the pivot
points, sliding surfaces, and spring ends with SAE 30W
motor oil. Keep the ball socket and latch mechanism clean.
Dirt or contamination can prevent proper operation of the
latching mechanism.
The load rating of the coupler and the necessary ball size
are listed on the trailer tongue. You must provide a hitch and
ball for your tow vehicle where the load rating of the hitch
and ball is equal to or greater than that of your trailer.
Also, the ball size must be the same as the coupler size. If
the hitch ball is too small, too large, is underrated, is loose
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 49
Trailer guidelines
or is worn, the trailer can come loose from the tow vehicle
and may cause death or serious injury.
the trailer tongue. Wood or concrete blocks may also
be used.
THE TOW VEHICLE, HITCH AND BALL MUST HAVE A
RATED TOWING CAPACITY EQUAL TO OR GREATER
THAN THE TRAILER gross vehicle Weight rating
(gvWr). IT IS ESSENTIAL THAT THE HITCH BALL BE
OF THE SAME SIZE AS THE COUPLER.
Coupling the trailer to the tow vehicle (Ball Coupler)
The ball size and load rating (capacity) are marked on the
ball. Hitch capacity is marked on the hitch.
WARNING
Coupler-to-hitch mismatch can result in uncoupling,
leading to death or serious injury.
Be sure the LOAD RATING of the hitch ball is equal or
greater than the load rating of the coupler.
Be sure the SIZE of the hitch ball matches the size of
the ball coupler.
WARNING
A worn, cracked or corroded hitch ball can fail while
towing and may result in death or serious injury.
„ Lubricate the hitch ball and the inside of the coupler with
a thin layer of automotive bearing grease.
„ Slowly back up the tow vehicle so that the hitch ball is
near or aligned under the coupler.
„ Using the jackstand at the front of trailer (tongue), turn
the jackstand crank handle to raise the trailer. If the ball
coupler does not line up with the hitch ball, adjust the
position of the tow vehicle.
„ Open the coupler locking mechanism. Ball couplers have
a locking mechanism with an internal moving piece and
an outside handle. In the open position, the coupler is
able to drop fully onto the hitch ball.
„ Lower the trailer (Figure D) until the coupler fully engages
the hitch ball.
2-INCH
TRAILER
COUPLER
TOW
VEHICLE
Before coupling trailer, inspect the hitch ball for wear,
corrosion and cracks.
Replace worn or damaged hitch ball.
WARNING
A loose hitchball nut can result in uncoupling, leading
to death or serious injury.
Be sure the hitch ball is tight to the hitch before coupling
the trailer.
„ Rock the ball to make sure it is tightened to the hitch,
and visually check that the hitch ball nut is solid against
the lock washer and hitch frame.
„ Wipe the inside and outside of the coupler. Clean and
visually inspect it for cracks and deformations. Feel the
inside of the coupler for worn spots and pits.
„ Be sure the coupler is secured tightly to the tongue of the
trailer. All coupler fasteners must be visibly solid against
the trailer frame.
„ The bottom surface of the coupler must be above the top
of the hitch ball. Use the tongue jackstand to support
2-INCH
BALL
Figure D. Ball Hitch Coupling Mechanism
„ Engage the coupler locking mechanism. In the engaged
position, the locking mechanism securely holds the
coupler to the hitch ball.
„ Insert a pin or lock through the hole in the locking
mechanism.
„ Be sure the coupler is all the way on the hitch ball and
the locking mechanism is engaged. A properly engaged
locking mechanism will allow the coupler to raise the rear
of the tow vehicle. Using the trailer jackstand, verify that
you can raise the rear of the tow vehicle by 1 inch after
the coupler is locked to the hitch.
„ Lower the trailer so that its entire tongue weight is held
by the hitch.
„ Raise the jackstand to a height where it will not interfere
with the road.
page 50 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
Trailer guidelines
Breakaway Brake System
NOTICE
Overloading can damage the tongue jack. DO NOT
use the tongue jack to raise the tow vehicle more than
one inch.
If the coupler cannot be secured to the hitch ball, do not
tow the trailer. Call your dealer for assistance. Lower the
trailer so that its entire tongue weight is held by the hitch and
continue retracting the jack to its fully retracted position.
Attaching Safety Chain
If the coupler or hitch fails, a properly connected and
working breakaway brake system (Figure F) will apply the
hydraulic brakes on the trailer. The safety chains will keep
the tow vehicle attached and as the brakes are applied at
the trailer’s axles, the trailer/tow vehicle combination will
come to a controlled stop.
Connect Cable
to Tow Vehicle
Breakaway Lever
Connect Cable
to Tow Vehicle
Visually inspect the safety chains and hooks for wear or
damage. Replace worn or damaged safety chains and
hooks before towing.
Hydraulic Actuator
Attach the safety chains so that they:
Breakaway Switch
Electric Actuator
•Cross underneath the coupler. See Figure E.
TOW
VEHICLE
Figure F. Breakaway Brake System
Breakaway Cable Surge Brake System
TRAILER
TONGUE
IMPORTANT!
SAFETY CHAIN
MASTER LINK
CROSS BOTH
SAFETY CHAINS
Figure E. Attaching Safety Chain (Ball Hitch)
•Loop around a frame member of the tow vehicle or holes
provided in the hitch system (DO NOT attach them to
an interchangeable part of the hitch assembly).
•Have enough slack to permit tight turns, but not be
close to the road surface, so if the trailer uncouples, the
safety chains can hold the tongue up above the road
.
WARNING
Improper rigging of the safety chains can result in
loss of control of the trailer and tow vehicle, leading
to death or serious injury, if the trailer uncouples from
the tow vehicle.
• Fasten chains to frame of tow vehicle. DO NOT fasten
chains to any part of the hitch unless the hitch has
holes or loops specifically for that purpose.
• Cross chains underneath hitch and coupler with
enough slack to permit turning and to hold tongue
up, if the trailer comes loose.
The breakaway brake system includes a brake cable
connected to the tow vehicle on one end and to the
emergency brake lever located on the hydraulic actuator
on the other end.
WARNING
• An ineffective breakaway brake system can result in
a runaway trailer, leading to death or serious injury,
if the coupler or ball hitch fails.
• Connect the breakaway cable to the tow vehicle and
NOT to the hitch, ball or support.
• Before towing the trailer, test the function of the
breakaway brake system. If the breakaway brake
system is not working, DO NOT tow the trailer. Have
it serviced or repaired.
NOTICE
DO NOT tow the trailer with the breakaway brake
system ON because the brakes will overheat which
can result in permanent brake failure.
NOTICE
Replace the breakaway brake battery (if equipped) at
intervals specified by manufacturer.
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 51
Trailer guidelines
Connecting trailer lights
pINtle hItCh CoUpler
Connect the trailer lights to the tow vehicle’s electrical
system using the electric connectors at the front of the
trailer (tongue). Refer to the wiring diagram shown in the
trailer wiring diagram section of this manual. Before towing
the trailer check for the following:
A pintle eye coupler (Figure G) connects to a pintle-hook
hitch that is located on or under the rear bumper of the tow
vehicle. This system of coupling a trailer to a tow vehicle is
sometimes referred to as a “lunette eye, tow ring or G.I.
hitch.”
„ Running lights (turn on tow vehicle headlights).
„ Brake Lights (step on tow vehicle brake pedal).
„ Backup Lights (place tow vehicle gear shift in reverse).
„ Turn Signals (activate tow vehicle directional signal
lever).
WARNING
Improper electrical connection between the tow vehicle
and the trailer will result in inoperable lights and electric
brakes, and can lead to collision.
Before each tow:
• Check that the taillights, brake lights and turn signals
work.
• Check that the electric brakes work by operating the
brake controller inside the tow vehicle.
Uncoupling the Ball hitch
Follow these steps to uncouple ball hitch from tow
vehicle:
„ Block trailer tires to prevent the trailer from rolling, before
jacking the trailer up.
„ Disconnect the electrical connector.
„ Disconnect the breakaway brake switch cable. Promptly
replace the pullpin in the switchbox.
„ Before extending jackstand, make certain the ground
surface below the jackstand foot will support the tongue
load.
„ Rotate the jackstand handle (or crank) clockwise. This
will slowly extend the jack and transfer the weight of the
trailer tongue to the jack.
Figure G. Pintle Hitch Coupler
A pintle hitch trailer may be fitted with a tongue jackstand
that can raise and lower the coupler. The tongue jack is
mounted to the A-frame (front or tongue) part of the trailer.
By rotating the jack handle clockwise, the jack will extend
and raise the tongue of the trailer.
The load rating of the coupler and the necessary pintle
hitch size are listed on the trailer tongue. You must provide
a pintle hitch and pintle coupler for your tow vehicle, where
the load rating of the pintle hitch and pintle coupler is equal
to or greater than that of your trailer.
Also, the pintle hitch size must be the same as the pintle
coupler size. If the hitch is too small, too large, underrated,
loose or worn, the trailer can come loose from the tow
vehicle, and may cause death or serious injury.
Pintle Coupler and Pintle Hook
Before each tow, check the locking device that secures the
coupler to the pintle hook assembly.
The pintle hook lever must be able to operate freely and
automatically snap into place into the latched position.
Lightly oil the pivot points and sliding surfaces with SAE30W
motor oil to prevent rust and help ensure proper operation
of the latching mechanism.
If you see or feel evidence of wear, such as flat spots,
deformations, pitting or corrosion, on the pintle hook or
coupler, immediately have your dealer inspect them to
determine the proper action to prevent possible failure of
page 52 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
Trailer guidelines
the ball andcoupler system. All bent or broken coupler parts
must be replaced before towing the trailer.
THE TOW VEHICLE, PINTLE HITCH AND PINTLE
COUPLER MUST HAVE A RATED TOWING CAPACITY
EQUAL TO OR GREATER THAN THE TRAILER Gross
vehicle Weight rating (gvWr).
IT IS ESSENTIAL THAT THE PINTLE HITCH BE OF THE
SAME SIZE AS THE PINTLE COUPLER.
The coupler size and load rating (capacity) are marked on
the coupler. Hitch capacity is marked on the hitch.
WARNING
A defective pintle hitch not properly fastened can result
in uncoupling, leading to death or serious injury.
Be sure the pintle hook is securly tighten to the tow
vehicle before coupling the trailer.
Coupling trailer to tow vehicle (pintle Coupler)
„ Slowly back up the tow vehicle so that the pintle
hitch hook is near or aligned under the pintle eye ring
coupler.
Coupler-to-hitch mismatch can result in uncoupling,
leading to death or serious injury.
„ Using the jackstand at the front of trailer (tongue), turn
the jackstand crank handle to raise the trailer. If the pintle
eye coupler does not line up with the pintle hitch hook,
adjust the position of the tow vehicle.
Be sure the LOAD RATING of the pintle hitch hook is
equal or greater than the load rating of the pintle eye
coupler.
„ OPEN the pintle hook locking mechanism (Figure H).
Place the hook inside the eye coupler. CLOSE the pintle
hook mechanism.
WARNING
Be sure the SIZE of the pintle hitch hook matches the
size of the pintle eye coupler.
TRAILER
TONGUE
PINTLE
HOOK
TOW
VEHICLE
WARNING
A worn, cracked or corroded pintle hitch hook can fail
while towing, and may result in death or serious injury.
Before coupling trailer, inspect the pintle hitch hook for
wear, corrosion and cracks.
Replace worn or damaged pintle hitch hook.
„ Rock the pintle eye coupler to make sure it is secured
tightly to the hitch.
„ Wipe the inside and outside of the pintle coupler. Clean
and inspect it visually for cracks and deformations. Feel
the inside of the coupler for worn spots and pits.
„ Be sure the coupler is secured tightly to the tongue of the
trailer. All coupler fasteners must be visibly solid against
the trailer frame.
„ Raise the bottom surface of the coupler to be above the
top of the pintle hitch hook. Use the tongue jackstand
to support the trailer tongue. Wood or concrete blocks
may also be used.
SAFETY CHAIN
MASTER LINK
PINTLE
RING “EYE”
SAFETY
CHAIN
IMPORTANT!
CROSS BOTH
SAFETY CHAINS
Figure H. Attaching Safety Chain (Pintle Hitch)
„ Insert a pin or lock through the hole in the locking
mechanism.
„ Be sure the pintle hook is inserted completely through
the eye ring and the locking mechanism is engaged.
A properly engaged locking mechanism will allow the
coupler to raise the rear of the tow vehicle. Using the
trailer jack, test to see that you can raise the rear of the
tow vehicle by1-inch after the coupler is locked to the
hitch.
„ Lower the trailer so that its entire tongue weight is held
by the hitch.
„ Raise the jackstand to a height where it will not interfere
with the road.
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 53
Trailer guidelines
TIRE SAFETY
Unsafe tires, lug Nuts or Wheels
Trailer tires and wheels are more likely to fail than car tires
and wheels because they carry a heavier load. Therefore,
it is essential to inspect the trailer tires before each tow.
If a tire has a bald spot, bulge, cuts, is showing any cords,
or is cracked, replace the tire before towing. If a tire has
uneven tread wear, take the trailer to a dealer service
center for diagnosis.
Uneven tread wear can be caused by tire imbalance, axle
misalignment or incorrect inflation.
Tires with too little tread will not provide adequate tracking
on wet roadways and can result in loss of control, leading
to death or serious injury.
Improper tire pressure causes an unstable trailer and
can result in a tire blowout and loss of control. Therefore,
before each tow you must also check the tire pressure. Tire
pressure must be checked when tires are cold.
Allow 3 hours cool-down after driving as much as 1 mile at
40 mph before checking tire pressure. Trailer tires will be
inflated to higher pressures than passenger vehicle tires.
Since trailer wheels and lug nuts (or bolts) are subjected
to greater side loads than automobile wheels, they are
more prone to loosen. Before each tow, check to make
sure they are tight.
The proper tightness (torque) for lug nuts is listed in the
lug nut tightening section of this manual. Use a torque
wrench to tighten the lug nuts. If you do not have a torque
wrench, use a lug wrench (from your tow vehicle) and
tighten the nuts as much as you can. Then have a service
garage or trailer dealer tighten the lug nuts to the proper
torque.
WARNING
Metal creep between the wheel rim and lug nuts will
cause rim to loosen and could result in a wheel coming
off, leading to death or serious injury.
Lug nuts are also prone to loosen after first being
assembled. When driving a new trailer (or after wheels
have been remounted), check to make sure they are tight
after the first 10, 25 and 50 miles of driving and before
each tow thereafter.
Failure to perform this check can result in a wheel parting
from the trailer and a crash, leading to death or serious
injury.
WARNING
Lug nuts are prone to loosen after initial installation,
which can lead to death or serious injury.
Check lug nuts for tightness on a new trailer or when
wheel(s) have been remounted after the first 10, 25
and 50 miles of driving.
WARNING
Improper lug nut torque can cause a wheel parting from
the trailer, leading to death or serious injury.
Be sure lug nuts are tight before each tow.
WARNING
Improper tire pressure can result in a blowout and loss
of control, which can lead to death or serious injury.
Be sure tires are inflated to pressure indicated on side
wall before towing trailer.
Determining load limit of trailer
Determining the load limits of a trailer includes more than
understanding the load limits of the tires alone. On all
trailers there is a Federal certification/VIN label that is
located on the forward half of the left (road) side of the unit.
This certification/VIN label will indicate the trailer’s Gross
Vehicle Weight Rating (GVWR). This is the most weight
the fully loaded trailer can weigh. It will also provide the
Gross Axle Weight Rating (GAWR). This is the most a the
axle can weigh.
Tighten lug nuts before each tow.
page 54 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
Trailer guidelines
There is a vehicle placard (Figure I) located in the same
location as the certification label described above. This
placard provides tire and loading information. In addition,
this placard will show a statement regarding maximum
cargo capacity.
TIRE AND LOADING INFORMATION
The weight of cargo should never exceed XXX kg. Or XXX lbs.
TIRE
FRONT
REAR
SPARE
SIZE
COLD TIRE PRESSURE
SEE OWNER’S
MANUAL FOR
ADDITIONAL
INFORMATION
Figure I. Trailer Tire Placard
If additional work items (hoses, tools, clamps etc.) are
going to be added to the trailer, be sure they are distributed
evenly to prevent overloading front to back and side to side.
Heavy items should be placed low and as close to the axle
positions as reasonable. Too many items on one side may
overload a tire.
Excessive loads and/or underinflation cause tire overloading
and, as a result, abnormal tire flexing occurs. This situation
can generate an excessive amount of heat within the tire.
Excessive heat may lead to tire failure. It is the air pressure
that enables a tire to support the load, so proper inflation
is critical. The proper air pressure may be found on the
certification/VIN label and/or on the Tire and Loading
Information placard. This value should never exceed the
maximum cold inflation pressure stamped on the tire.
Perform the following steps to determine the load limit of
your trailer.
Step 1.
Locate the statement, “The weight of cargo should never
exceed XXX kg or XXX lbs.,” on your vehicle’s Tire and
Loading Information placard (Figure I). This value equals
the available amount of equipment load capacity.
Step 2.
Determine the weight of the equipment being loaded
on the tow vehicle. That weight may not safely exceed
the available equipment load capacity. The trailer’s Tire
Information Placard is attached adjacent to or near the
trailer’s VIN (Certification) label at the left front of the trailer
(See Figure I).
Determining load limit of tow vehicle
Step 1.
Locate the statement, “The combined weight of occupants
and cargo should never exceed XXX lbs.,” on your vehicle’s
placard.
Step 2.
Determine the combined weight of the driver and
passengers who will be riding in your vehicle.
Step 3.
Subtract the combined weight of the driver and passengers
from XXX kilograms or XXX pounds.
Step 4.
The resulting figure equals the available amount of cargo
and luggage capacity. For example, if the “XXX” amount
equals 1400 lbs. and there will be five 150 lb. passengers
in your vehicle, the amount of available cargo and luggage
capacity is 650 lbs. (1400-750 (5 x 150) = 650 lbs.).
Step 5.
Determine the combined weight of luggage and cargo
being loaded on the vehicle. That weight may not safely
exceed the available cargo and luggage capacity calculated
in Step 4.
If your vehicle will be towing a trailer, load from your trailer
will be transferred to your vehicle. Consult the tow vehicle’s
manual to determine how this weight transfer reduces the
available cargo and luggage capacity of your vehicle.
Studies of tire safety show that maintaining proper tire
pressure, observing tire and vehicle load limits (not carrying
more weight in your vehicle than your tires or vehicle can
safely handle), avoiding road hazards and inspecting tires
for cuts, slashes and other irregularities are the most
important things you can do to avoid tire failure, such as
tread separation or blowout and flat tires. These actions,
along with other care and maintenance activities, can
also:
„ Improve vehicle handling.
„ Help protect you and others from avoidable breakdowns
and accidents.
„ Improve fuel economy.
„ Increase the tire life.
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 55
Trailer guidelines
Use the information contained in this section to make tire
safety a regular part of your vehicle maintenance routine.
Recognize that the time you spend is minimal compared
with the inconvenience and safety consequences of a flat
tire or other tire failure.
tIre FUNDameNtalS
Federal law requires tire manufacturers to place standardized
information on the sidewall of all tires (Figure J). This
information identifies and describes the fundamental
characteristics of the tire and also provides a tire
identification number for safety standard certification and
in case of a recall.
Figure J. Standard Tire Sidewall Information
P: The “P” indicates the tire is for passenger vehicles.
Next number: This three-digit number gives the width in
millimeters of the tire from sidewall edge to sidewall edge.
In general, the larger the number, the wider the tire.
Next number: This two-digit number, known as the aspect
ratio, gives the tire’s ratio of height to width. Numbers of
70 or lower indicate a short sidewall for improved steering
response and better overall handling on dry pavement.
P: The “R” stands for radial. Radial ply construction of tires
has been the industry standard for the past 20 years.
Next number: This two-digit number is the wheel or rim
diameter in inches. If you change your wheel size, you
will have to purchase new tires to match the new wheel
diameter.
Next number: This two- or three-digit number is the tire’s
load index. It is a measurement of how much weight each
tire can support. You may find this information in your
owner’s manual. If not, contact a local tire dealer. Note:
You may not find this information on all tires because it is
not required by law.
m+S: The “M+S” or “M/S” indicates that the tire has
some mud and snow capability. Most radial tires have
these markings; hence, they have some mud and snow
capability.
Speed Rating: The speed rating denotes the speed at
which a tire is designed to be driven for extended periods
of time. The ratings range from 99 miles per hour (mph) to
186 mph. These ratings are listed in Table A. Note: You may
not find this information on all tires because it is not required
by law.
table a. Speed Rating
letter rating
Speed Rating
Q
99 mph
R
106 mph
S
112 mph
T
118 mph
U
124 mph
H
130 mph
V
149 mph
W
168* mph
Y
186* mph
U.S. Dot tire Identification Number: This begins with the
letters “DOT” and indicates that the tire meets all federal
standards. The next two numbers or letters are the plant
code where it was manufactured, and the last four numbers
represent the week and year the tire was built. For example,
the numbers 3197 means the 31st week of 1997. The other
numbers are marketing codes used at the manufacturer’s
discretion. This information is used to contact consumers
if a tire defect requires a recall.
tire ply Composition and materials Used: The number of
plies indicates the number of layers of rubber-coated fabric
in the tire. In general, the greater the number of plies, the
more weight a tire can support. Tire manufacturers also
must indicate the materials in the tire, which include steel,
nylon, polyester, and others.
maximum load rating: This number indicates the
maximum load in kilograms and pounds that can be carried
by the tire.
maximum permissible Inflation pressure: This number
is the greatest amount of air pressure that should ever be
put in the tire under normal driving conditions.
page 56 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
Trailer guidelines
Uniform tire Quality grading Standards (UtQgS)
Treadwear Number: This number indicates the tire’s wear
rate. The higher the treadwear number is, the longer it
should take for the tread to wear down. For example, a tire
graded 400 should last twice as long as a tire graded 200.
traction letter: This letter indicates a tire’s ability to stop
on wet pavement. A higher graded tire should allow you
to stop your car on wet roads in a shorter distance than a
tire with a lower grade. Traction is graded from highest to
lowest as “AA”,”A”, “B”, and “C”.
temperature letter: This letter indicates a tire’s
resistance to heat. The temperature grade is for a tire that
is inflated properly and not overloaded. Excessive speed,
underinflation or excessive loading, either separately or
in combination, can cause heat build-up and possible tire
failure. From highest to lowest, a tire’s resistance to heat
is graded as “A”, “B”, or “C”.
Refer to Figure K for additional tire information for light
trucks.
load range: This information identifies the tire’s loadcarrying capabilities and its inflation limits.
Tire Safety Tips
„ Slow down if you have to go over a pothole or other
object in the road.
„ DO NOT run over curbs or other foreign objects in the
roadway, and try not to strike the curb when parking.
„ Check tire inflation pressure weekly during use to insure
the maximum tire life and tread wear.
„ DO NOT bleed air from tires when they are hot.
„ Inspect tires for uneven wear patterns on the tread,
cracks, foreign objects, or other signs of wear or
trauma.
„ Remove bits of glass and foreign objects wedged in
the tread.
„ Make sure your tire valves have valve caps.
„ alWaYS check tire pressure on tow vehicle and trailer
before towing. Check tire pressure at least once a
month.
„ DO NOT overload tow vehicle. Check the tire information
and loading placard for safe allowable tire loading
conditions.
Tire Repair
Tires for light trucks have other markings besides those
found on the sidewalls of passenger tires.
The proper repair of a punctured tire requires a plug for the
hole and a patch for the area inside the tire that surrounds
the puncture hole. Punctures through the tread can be
repaired if they are not too large, but punctures to the
sidewall should not be repaired. Tires must be removed
from the rim to be properly inspected before being plugged
and patched.
lt: The “LT” indicates the tire is for light trucks or trailers.
Replacing Worn or Damaged Tires
Figure K. UTQGS Tire Information
ST: An “ST” is an indication the tire is for trailer use only.
max. load Dual kg (lbs) at kPa (psi) Cold: This information
indicates the maximum load and tire pressure when the tire
is used as a dual, that is, when four tires are put on each
rear axle (a total of six or more tires on the vehicle).
max. load Single kg (lbs) at kPa (psi) Cold: This
information indicates the maximum load and tire pressure
when the tire is used as a single.
Replace the tire before towing the trailer if the tire treads
have less than 1/16 inch depth or the telltale bands are
visible. Check inflation pressure weekly during use to insure
the maximum tire life and tread wear. A bubble, cut or bulge
in a side wall can result in a tire blowout. Inspect both side
walls of each tire for any bubble, cut or bulge; and replace
a damaged tire before towing the trailer.
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 57
Trailer guidelines
Table B below will help pinpoint the causes and solutions
of tire wear problems.
table B. Tire Wear Troubleshooting
Wear Pattern
Cause
Solution
Center Wear
Over inflation.
Adjust pressure to particular
load per tire manufacturer.
Edge Wear
Under inflation.
Adjust pressure to particular
load per tire manufacturer.
Side Wear
Loss of camber
or overloading.
Make sure load does not
exceed axle rating.
Align wheels.
Toe Wear
Incorrect toe-in.
Align wheels.
Cupping
Out-of-balance.
Check bearing adjustment
and balance tires.
Wheel lockup and
tire skidding.
Avoid sudden stops when
possible and adjust brakes.
Flat Spots
WARNING
ALWAYS wear safety glasses when
removing or installing force fitted parts. DO
NOT attempt to repair or modify a wheel.
DO NOT install an inner-tube to correct a
leak through through the rim. If the rim is
cracked, the air pressure in the inner tube may cause
pieces of the rim to explode (break off) with great force
and cause serious eye or bodily injury.
NOTICE
Never use an pneumatic air gun to tighten wheel
lug nuts.
Over-tightening lug nuts will result in breaking the studs
or permanently deforming the mounting stud holes in
the wheels.
WARNING
Lug nuts are prone to loosen after initial installation,
which can lead to death or serious injury. Check all
wheel lug nuts periodically.
lug Nut torque requirements
It is extremely important to apply and maintain proper wheel
mounting torque on the trailer. Be sure to use only the
fasteners matched to the cone angle of the wheel. Proper
procedure for attachment of the wheels is as follows:
1. Start all wheel lug nuts by hand.
2. Torque all lug nuts in sequence. See Figure L. DO
NOT torque the wheel lug nuts all the way down.
Tighten each lug nut in 3 separate passes as defined
by Table C.
3. Check to see if the lug nuts are tight after the first 10,
25 and 50 miles of driving and before each tow
thereafter
Wheel Rims
If the trailer has been struck, or impacted, on or near the
wheels, or if the trailer has struck a curb, inspect the rims for
damage (i.e. being out of round); and replace any damaged
wheel. Inspect the wheels for damage every year, even if
no obvious impact has occurred.
Wheels, Bearings and lug Nuts
A loose, worn or damaged wheel bearing is the most
common cause of brakes that grab.
To check wheel bearings, jack trailer and check wheels
for side-to-side looseness. If the wheels are loose, or spin
with a wobble, the bearings must be serviced or replaced.
Check inflation pressure weekly during use to insure the
maximum tire life and tread wear. Most trailer axles are
built with sealed bearings that are not serviceable. Sealed
bearings must be replaced as complete units.
Figure L. Wheel Lug Nuts Tightening Sequence
page 58 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
Trailer guidelines
table C. Tire Torque Requirements
Wheel Size
First Pass
Ft-lBS
Second Pass
Ft-lBS
Third Pass
Ft-lBS
12"
20-25
35-40
50-65
13"
20-25
35-40
50-65
14"
20-25
50-60
90-120
15"
20-25
50-60
90-120
16"
20-25
50-60
90-120
Replace any broken or burned-out lamps as necessary.
Check the wire harness for cuts, fraying or other damage.
If it needs replacing, contact your dealer.
WARNING
Improper operating taillights, stoplights and turn signals
can cause collisions.
Check all lights before each tow.
lights and Signals
Before each tow, check the trailer taillights, stoplights, turn
signals and any clearance lights for proper operation.
Figure M. Trailer to Tow Vehicle Wiring Diagram
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 59
Generator Wiring Diagram
Figure 69. Generator Wiring Diagram
page 60 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
600 vac auto transformer Wiring Diagram
3-POLE 70 AMPS CIRCUIT BREAKER
DISJONCTEUR 70 AMPS À 3 PÔLES
2” (50.8 MM)
2” (50.8 MM)
2” (50.8 MM)
2” (50.8 MM)
1/0 AWG RED
1/0 AWG RED
1/0 AWG ROUGE
1/0 AWG ROUGE
1/0 AWG BLACK
1/0 AWG NOIR
1/0 AWG BLACK
1/0 AWG NOIR
1/0 AWG BLUE
1/0 AWG BLUE
1/0 AWG BLEU
1/0 AWG BLEU
1/0 AWG WHITE
1/0 AWG WHITE
1/0 AWG BLANC
1/0 AWG BLANC
2 AWG GREEN
2 AWG GREEN
2 AWG VERT
2 AWG VERT
Figure 70. 600 VAC Auto Transformer Wiring Diagram
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 61
Engine Wiring Diagram
Figure 71. Engine Wiring Diagram
page 62 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
controller Wiring Diagram
Figure 72. Controller Wiring Diagram
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 63
battery Charger Wiring Diagram
BLACK 14 AWG. LINE (L)120VAC INPUT
WHITE 14 AWG. NEUTRAL (N)
A
B
3
1
2
4
GREEN 14 AWG. GROUND (G)
TO CHASSIS
GROUND
GREEN 16 AWG.
TO STARTER “B”
TERMINAL
RED 16 AWG.
3
B
A
BATTERY CHARGER
120 VAC INPUT
RECEPTACLE
2
4
1
NOTES:
1
NEMA 5-15, 15A, 120 VAC, P/N EE6176 (HBL5278C/HUBBLE RECEPTACLE).
2
RECEPTACLE IS MOUNTED ON OUTPUT TERMINAL PANEL ASSY.
3
20 AMP, 5-20R RECEPTACLE, P/N EE6131 (HBL5369C/HUBBLE RECEPTACLE).
4
CORD, CAROL 3/C 14 AWG., P/N EE56557.
page 64 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
jacket water heater Wiring Diagram
BLACK 14 AWG. LINE (L)120VAC INPUT
WHITE 14 AWG. NEUTRAL (N)
A
B
3
1
2
4
GREEN 14 AWG. GROUND (G)
BLOCK HEATER
(P/N 44558)
BLACK 14 AWG.
LINE (L)120VAC INPUT
WHITE 14 AWG.
NEUTRAL (N)
3
TEMP.
SWITCH
120 VAC
HEATING
ELEMENT
GREEN 14 AWG.
GROUND (G)
B
GROUND
JACKET WATER HEATER
120 VAC INPUT
RECEPTACLE
A
4
2
1
NOTES:
1
NEMA 5-15, 15A, 120 VAC, P/N EE6176 (HBL5278C/HUBBLE RECEPTACLE).
2
RECEPTACLE IS MOUNTED ON OUTPUT TERMINAL PANEL ASSY.
3
20 AMP, 5-20R RECEPTACLE, P/N EE6131 (HBL5369C/HUBBLE RECEPTACLE).
4
CORD, CAROL 3/C 14 AWG., P/N EE56557.
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 65
Troubleshooting (Generator)
Practically all breakdowns can be prevented by proper handling and maintenance inspections, but in the event of a
breakdown, use Table 16 shown below for diagnosis of the Generator. If the problem cannot be remedied, consult our
company’s business office or service plant.
Symptom
No Voltage Output
Low Voltage Output
High Voltage Output
Circuit Breaker Tripped
Table 16. Generator Troubleshooting
Possible Problem
Solution
AC Voltmeter defective?
Check output voltage using a voltmeter.
Is wiring connection loose?
Check wiring and repair.
Is AVR defective?
Replace if necessary.
Defective Rotating Rectifier? Check and replace.
Defective Exciter Field?
Check for approximately 17.3 ohms across J & K on CN1
Is engine speed correct?
Turn engine throttle lever to “High”.
Is wiring connections loose? Check wiring and repair.
Defective AVR?
Replace if necessary.
Is wiring connections loose? Check wiring and repair.
Defective AVR?
Replace if necessary.
Short Circuit in load?
Check load and repair.
Over current?
Confirm load requirements and reduce.
Defective circuit breaker?
Check and replace.
Over current Relay actuated? Confirm load requirement and replace.
page 66 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
Troubleshooting (Diagnostic lamp)
The engine controller of this generator diagnoses problems
that arise from the engine control system and the engine
itself. Press the diagnostic button (Figure 73) on the
diagnostic panel to determine if an engine malfunction has
occurred.
Figure 73. Diagnostic Panel
Method of Operation
1. Normally, the diagnostic lamp will be dimly lit when
the MPEC Control Switch is placed in the MANUAL
position.
2. If engine trouble occurs, the diagnostic lamp will be
brightly lit as long as the control switch is left in the
manual position.
3. The diagnostic lamp will indicate that an engine
malfunction has occurred.
NOTICE
For a complete understanding of error codes and
troubleshooting procedures, refer to the enclosed
engine instruction manual.
NOTICE
If the engine is cranked while the diagnostic switch is in
the “ON” position, the engine will not be stopped even if
the starter switch is turned to the “OFF” position. In such
case, turn the diagnostic switch to the “OFF” position.
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 67
Explanation of Code in Remarks Column
The following section explains the different symbols and
remarks used in the Parts section of this manual. Use the
help numbers found on the back page of the manual if there
are any questions.
NOTICE
The contents and part numbers listed in the parts
section are subject to change without notice. Multiquip
does not guarantee the availability of the parts listed.
Sample partS liSt
NO.
1
2%
2%
3
4
part NO. part Name
QtY. remarKS
12345
BOLT......................1 .....INCLUDES ITEMS W/%
WASHER, 1/4 IN............NOT SOLD SEPARATELY
12347
WASHER, 3/8 IN....1 .....MQ-45T ONLY
12348
HOSE ..................A/R ...MAKE LOCALLY
12349
BEARING ..............1 .....S/N 2345B AND ABOVE
NO. Column
QtY. Column
Numbers Used — Item quantity can be indicated by a
number, a blank entry, or A/R.
A/R (As Required) is generally used for hoses or other
parts that are sold in bulk and cut to length.
A blank entry generally indicates that the item is not sold
separately. Other entries will be clarified in the “Remarks”
Column.
remarKS Column
Some of the most common notes found in the “Remarks”
Column are listed below. Other additional notes needed
to describe the item can also be shown.
assembly/Kit — All items on the parts list with the
same unique symbol will be included when this item is
purchased.
Unique Symbols — All items with same unique
symbol
Indicated by:
“INCLUDES ITEMS W/(unique symbol)”
(@, #, +, %, or >) in the number column belong to the
same assembly or kit, which is indicated by a note in the
“Remarks” column.
Serial Number Break — Used to list an effective serial
number range where a particular part is used.
Duplicate item Numbers — Duplicate numbers indicate
multiple part numbers, which are in effect for the same
general item, such as different size saw blade guards in
use or a part that has been updated on newer versions
of the same machine.
NOTICE
When ordering a part that has more than one item
number listed, check the remarks column for help in
determining the proper part to order.
part NO. Column
Numbers Used — Part numbers can be indicated by a
number, a blank entry, or TBD.
TBD (To Be Determined) is generally used to show a
part that has not been assigned a formal part number
at the time of publication.
A blank entry generally indicates that the item is not sold
separately or is not sold by Multiquip. Other entries will
be clarified in the “Remarks” Column.
Indicated by:
“S/N XXXXX AND BELOW”
“S/N XXXX AND ABOVE”
“S/N XXXX TO S/N XXX”
Specific model Number Use — Indicates that the part
is used only with the specific model number or model
number variant listed. It can also be used to show a
part is NOT used on a specific model or model number
variant.
Indicated by:
“XXXXX ONLY”
“NOT USED ON XXXX”
“make/Obtain locally” — Indicates that the part can
be purchased at any hardware shop or made out of
available items. Examples include battery cables, shims,
and certain washers and nuts.
“Not Sold Separately” — Indicates that an item cannot
be purchased as a separate item and is either part of an
assembly/kit that can be purchased, or is not available
for sale through Multiquip.
page 68 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
Suggested Spare Parts
dca125USi3CAN WHISPERWATT GENERATOR with
ISUZU 4HK1X DIESEL engine
1 to 3 units
Qty.P/N
Description
5............1132402322...........CARTRIDGE, oil filter
3............0602046684...........ELEMENT, AIR (outer)
3............P777639................ELEMENT, AIR (inner)
1............8980627130...........BELT, FAN
3............m3310502603........radiator hose, upper
3............m3310502703........radiator hose, lower
3............8980714010...........fuel filter, feed pump
3............8981430410...........filter fuel, element main
3............8980742880...........filter fuel, element pre
1............0602122272...........UNIT, OIL PRESSURE
1............0602123260...........UNIT, WATER TEMPERATURE
1............9095720140...........PACKING, WATER TEMPERATURE
1............8121468300...........SEnsor, water temperature
1............8980274560...........SEnsor, OIL pressure
1............1096300850...........gasket, oil pressure sensor
1............8971256011...........SWITCH, OVERHEAT
1............0601870440...........circuit breaker, 1p, 20 amp
1............0601870441...........circuit breaker 2p, 50 amp
1............0601820608...........automatic Voltage Regulator
3............0601806671...........fuse, 15 amp
1............0601806644...........fuse, 30 amp
1............0601806640...........fuse, 65 amp
2............ly2DUS12VDC.....relay
NOTICE
Part number on this Suggested Spare Parts list may
supersede/replace the P/N shown in the text pages of
this book.
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 69
GENERATOR ASSY.
page 70 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
GENERATOR ASSY.
NO. PART NO.
1
C0110001002
1-1#
1-2#8131070013
1-3# 8131611014
1-4# 8131015003
1-5# 0012112035
1-6# 0042612000
1-7# 8101026013
1-8#0601821349
1-9# 0601822601
1-10# 8001020004
1-11# 8001020504
1-12# 012210020
1-13# 0040010000
1-14# 0601000209
1-15#0071906312
2
C0130000503
30845041804
4
8131315202
5
8101350013
6
0012110060
7
0042610000
8
031110160
9
0010112035
10
0040012000
11
031112230
128131310104
13
8131312204
14
8131331003
15
0105050616
16
8101333003
17
0010006030
18
0040006000
19
952404470
20
M3163400503
21
0010310075
22
030210250
23
012010030
24
M3163600003
25
012010030
26
012010030
27
8131332014
280600815000
29
0605000063
30
0030016000
30A 0040016000
PART NAME
QTY. REMARKS
ROTOR ASSY...............................1........INCLUDES ITEMS W/#
FIELD ASSY
1
FAN
1
COUPLING DISK
8
BALANCING PLATE......................1........PURCHASE ITEM 1-14 AS A SET
HEX HEAD BOLT
10
WASHER, LOCK
10
SET PLATE, RECTIFIER..............1........PURCHASE ITEM 1-14 AS A SET
RECTIFIER
2
SURGE ABSORBER
1
WASHER, INSULATOR
1
WASHER, INSULATOR
1
HEX HEAD BOLT..........................4........REPLACES P/N 0010110020
WASHER, LOCK
4
BALANCING WEIGHT KIT
1
BEARING
1
STATER ASSY
1
GROMMET
2
END BRACKET
1
FIELD ASSY, EXCITER
1
HEX HEAD BOLT
4
WASHER, LOCK
4
WASHER, FLAT............................4........REPLACES P/N 0041210000
HEX HEAD BOLT
6
WASHER, LOCK
6
WASHER, FLAT............................6........REPLACES P/N 0041212000
COVER,BEARING
1
GASKET, BEARING
1
COVER, END BRACKET
1
HEX HEAD BOLT.........................10.......REPLACES P/N 0017106012
COVER, END BRACKET
1
HEX HEAD BOLT..........................2........REPLACES P/N 0010106030
WASHER, LOCK
2
WASHER, FLAT............................2........REPLACES P/N 0041206000
COUPLING RING
1
HEX HEAD BOLT
8
WASHER, LOCK...........................8........REPLACES P/N 004251000
HEX HEAD BOLT.........................12.......REPLACES P/N 0012810030
COUPLING ADAPTER
1
HEX HEAD BOLT.........................12.......REPLACES P/N 0012810030
HEX HEAD BOLT.........................12.......REPLACES P/N 0012810030
COVER, FAN
1
NUT
1
RUBBER SUSPENSION
2
HEX NUT
2
WASHER, LOCK
2
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 71
control box ASSY.
88
page 72 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
control box ASSY.
NO. PART NO.
PART NAME
QTY.
REMARKS
1
M3213001802
CONTROL BOX..................................................1................S/N 9980000 AND BELOW
1
M3214000202
CONTROL BOX..................................................1................S/N 9980001 AND ABOVE
1-10330000210 EDGING
2
1-20330000280 EDGING
1
1-30330000340 EDGING
2
2
0601808827
CIRCUIT BREAKER, 3P 350A
1
2-1
0342604120
HEX SOCKET HEAD CAP SCREW
6
3
0021006080
MACHINE SCREW
4
4
0601823863
RELAY UNIT
2
5
7538070
MACHINE SCREW.............................................4................REPLACES P/N 0027104016
6
0601820608
AUTOMATIC VOLTAGE REGULATOR
1
7
0027105016
MACHINE SCREW
4
8
0601801124
CURRENT TRANSFORMER
3
9
011206020
HEX HEAD BOLT 6X20......................................6................REPLACES P/N 0027106020
10
0601820847
OVER CURRENT RELAY
1
11
0601820848
OVER CURRENT RELAY
1
12
0027104020
MACHINE SCREW
2
12A OEMAA8
HEX NUT............................................................2................REPLACES P/N 0207004000
13
0601802218
HOLDER, FUSE
1
13A 0601806671
FUSE, 15A
3
14
0027103020
MACHINE SCREW
2
150601815153 TERMINAL
1
16
0027104020
MACHINE SCREW
2
17
8121468300
SENSOR, INLET AIR TEMP................................1................REPLACES P/N 0603210240
18
M3260500503
SET PANEL, ELECTRIC PARTS
1
19
0016906016
HEX HEAD BOLT
4
208980710280 CONTROLLER...................................................1................REPLACES P/N 0602202686
21 M3260500604BRACKET
1
22
0016906016
HEX HEAD BOLT
4
23
0601831205
PUSH BUTTON SWITCH
1
24
0601831330
DIAGNOSTIC SWITCH
1
25
0016906016
HEX HEAD BOLT
4
260601821370 RECTIFIER.........................................................1................REPLACES P/N 0601823240
27
0027104020
MACHINE SCREW
1
28
ly2DUS12VDCRELAY................................................................2................REPLACES P/N 0601827656
28APTF08A
BASE..................................................................2................REPLACES P/N 0601823109
28BPYCA1
CLIP....................................................................4................REPLACES P/N 0601824400
29
0027104020
MACHINE SCREW
4
30
8972177780
SENSOR, BAROMETRIC PRESSURE..............1................REPLACES P/N 0602130220
31
7538070
MACHINE SCREW.............................................2................REPLACES P/N 0027104016
32
5825530444
RELAY, STARTER...............................................1................REPLACES P/N 0602201402
33
0027106016
MACHINE SCREW
2
345825500290 RELAY................................................................3................REPLACES P/N 0602201400
35
0027105016
MACHINE SCREW
3
36
8970119490
RELAY, GLOW PLUG.........................................1................REPLACES P/N 0602202685
37
0027105016
MACHINE SCREW
2
38
M3213500704
CONTROL BOX COVER
1
39
0016906016
HEX HEAD BOLT
8
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 73
control box ASSY. ( continued)
88
page 74 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
control box ASSY. (continued)
NO. PART NO.
PART NAME
QTY.
REMARKS
40
M3270100504
SELECTOR SWITCH 1
40A M3550002504
DECAL: SELECTOR SWITCH NUMBER
1
40B M3550002604
DECAL: SELECTOR SWITCH NUMBER
1
41
M3213602704
SWITCH BRACKET
1
42
M3213602804
SWITCH BRACKET
1
43
0027104035
MACHINE SCREW
4
43A OEMAA8
HEX NUT
4
44
7538070
MACHINE SCREW.............................................4................REPLACES P/N 0027104016
44A OEMAA8
HEX NUT............................................................4................REPLACES P/N 0207004000
45
0016906016
HEX HEAD BOLT
4
46
M3213602604
SWITCH COVER
1
46-1 0317700180
WEATHER STRIP
1
47
M3213602504
SWITCH COVER
1
48
0016906016
HEX HEAD BOLT
10
49
011008020
HEX HEAD BOLT...............................................10...............REPLACES P/N 0016908020
49A 0040508000
TOOTHED WASHER
1
50
M3223001203
CONTROL PANEL
1
51
0601807641
FREQUENCY METER, 45~65Hz 240V
1
52
0601808988
AC AMMETER, 0~200A/400A:5A
1
53
0601801040
CHANGE OVER SWITCH, AMMETER
1
54
0601806859
AC VOLTMETER, 0~600V
1
55
0601801041
CHANGE OVER SWITCH, VOLTMETER
1
56
0601840073
RHEOSTAT (VR), 2W 1K OHM
1
570601840100 KNOB..................................................................1................REPLACES P/N 0601840121
58
0602202641
CONTROLLER, ECU (CAN77)
1
59
0021004040
MACHINE SCREW
2
59A OEMAA8
HEX NUT............................................................2................REPLACES P/N 020700400
6082608
SWITCH..............................................................1................REPLACES P/N 0601831340
61
0602103092
ALARM LAMP
3
61A 0601810245
BULB, DC 18V
3
620602120095 TACHOMETER
1
63
0602122093
OIL PRESSURE GAUGE
1
64
0602123099
WATER TEMPERATURE GAUGE
1
65
0602121081
CHARGING AMMETER
1
66
0602125090
FUEL GAUGE
1
67
9826800370
PANEL LIGHT.....................................................1................REPLACES P/N 0601810141
68
0601831330
SWITCH, PANEL LIGHT
1
69
0601830710
SWITCH, ENGINE SPEED
1
70 M1223100004STOPPER
1
71 M3223100004STOPPER
1
72
0027105010
MACHINE SCREW
4
73
0027105010
MACHINE SCREW
4
74
M9220100004
SET SCREW
2
75
0080200007
SNAP RING
2
76
0602122272
UNIT, OIL PRESSURE
1
77 M9200100004ADAPTER
1
788943998582 ADAPTER...........................................................1................REPLACES P/N 0602020220
79
0602123267
UNIT, WATER TEMPERATURE
1
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 75
control box ASSY. ( continued)
88
page 76 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
control box ASSY. (continued)
NO. PART NO.
809095720140
81
0602120465
82
0601806644
83
0601806640
84
0601830762
85
M3246703004
86
M3357202002
87
M3357201802
88
M3358200303
89
0601831331
PART NAME
QTY.
REMARKS
PACKING............................................................1................REPLACES P/N 0602021109
PICK UP, TACHOMETER
1
FUSE, 30A
1
FUSE, 65A
1
SWITCH, FUEL PUMP
1
WIRE HARNESS. GENERATOR
1
WIRE HARNESS, ENGINE
1
WIRE HARNESS, CONTROLLER
1
WIRE HARNESS, COLD WEATHER KIT
1
SWITCH, COLD WEATHER KIT
1
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 77
ENGINE AND RADIATOR ASSY.
page 78 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
ENGINE AND RADIATOR ASSY.
NO. PART NO.
PART NAME
QTY.
REMARKS
1
M3924200054
ENGINE, ISUZU 4HK1X
1
1A
8980627130
FAN BELT...........................................................1................REPLACES P/N 0602015253
2
M3303200603
ENGINE FOOT
2
3
0105091025
HEX HEAD BOLT................................................8................REPLACES P/N 001031025
4
030210250
WASHER, LOCK................................................8................REPLACES P/N 0042510000
5
0605000060
RUBBER SUSPENSION
2
6
0030012000
HEX NUT
2
7
0040012000
WASHER, LOCK
2
8 M3923200114RADIATOR
1
8-10602011029 CAP
1
9 M9200100904PLUG
1
100150000016 O-RING
1
11
M3310202904
RADIATOR BRACKET
2
12
011008020
HEX HEAD BOLT................................................8................REPLACES P/N 0016908020
13
M3310202803
RADIATOR BRACKET
1
13A M3493114104
ACOUSTIC SHEET
1
14
0016910025
HEX HEAD BOLT
6
15
0016910025
HEX HEAD BOLT
4
16
M3310202104
RADIATOR BRACKET
1
17
011008020
HEX HEAD BOLT................................................2................REPLACES P/N 0016908020
18
M3310502603
RADIATOR HOSE, UPPER
1
19
M3310502703
RADIATOR HOSE, LOWER
1
20
0605515148
HOSE BAND
1
21
M3310600303
HOSE SUPPORT
1
22
0016906016
HEX HEAD BOLT
4
23
M3310600204
HOSE BRACKET
2
23A 0222100260
RUBBER SEAL
2
24
011206020
HEX HEAD BOLT................................................2................REPLACES P/N 0016906020
25
M3310203003
FAN BRACKET
1
25A0601850239 GROMMET
1
26
0016910025
HEX HEAD BOLT
4
27
0601822968
FAN MOTOR
2
28
0016910025
HEX HEAD BOLT
8
29
0602046258
AIR CLEANER
1
29A 0602046684
ELEMENT, AIR CLEANER, OUTER
1
29B P777639
ELEMENT, AIR CLEANER, INNER....................1................REPLACES P/N 0602046685
30
0602040650
INDICATOR, AIR CLEANER
1
31
M3373200204
BRACKET AIR CLEANER
1
32
011008020
HEX HEAD BOLT................................................2................REPLACES P/N 0016908020
33
0602040596
BAND, AIR CLEANER
2
34
011008020
HEX HEAD BOLT................................................4................REPLACES P/N 0016908020
35
020108060
HEX NUT............................................................4................REPLACES P/N 0207008000
36
M3373101203
HOSE, AIR CLEANER
1
37
M3373101103
HOSE, AIR CLEANER
1
38
M3326100104
BLOW BY PIPE
1
39
0605515146
HOSE BAND
1
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 79
ENGINE AND RADIATOR ASSY. (continued)
page 80 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
ENGINE AND RADIATOR ASSY. (continued)
NO. PART NO.
PART NAME
QTY.
REMARKS
40
0605515197
HOSE BAND
3
41
M3373100903
AIR DUCT HOSE
1
42
0605515231
HOSE BAND
1
43
0191701050
BLOW BY HOSE
1
44
0605515149
HOSE BAND
2
45
M9100000204
HOSE JOINT
1
46
0602021731
SEAL WASHER
1
47
7812014003B
DRAIN JOINT.....................................................1................REPLACES P/N M2320300103
480802011104 PLUG..................................................................1................REPLACES P/N M9200200004
490150000018 O-RING
1
50
011206020
HEX HEAD BOLT................................................2................REPLACES P/N 0016906020
51
0199102250
DRAIN HOSE
1
52
0605515170
HOSE BAND.......................................................2................REPLACES P/N 0605515106
530602022581 ADAPTER
1
54
0602022561
90° ELBOW
1
550603306590 CONNECTOR
1
56
0603300285
LOCK NUT
1
570605511395 VALVE
1
58
0603306395
HOSE JOINT
1
590602021070 CAP
1
60
0269200800
DRAIN HOSE
1
61
M3323500004
BRACKET, OIL FILTER 1
62
0016910025
HEX HEAD BOLT
2
63
8973243861
OIL FILTER.........................................................1................REPLACES P/N 0602041007
63A 1132402322
CARTRIDGE, OIL FILTER..................................1................REPLACES P/N 0602041221
64
0010110120
HEX HEAD BOLT
2
64A 0040010000
WASHER, LOCK
2
64B 031110160
WASHER, FLAT..................................................2................REPLACES P/N 0041210000
65
0010110150
HEX HEAD BOLT
2
65A 0040010000
WASHER, LOCK
2
65B 031110160
WASHER, FLAT..................................................2................REPLACES P/N 0041210000
660602022530 ADAPTER
4
68
0192101100
HOSE ASSY........................................................2................S/N 8510246 AND BELOW
68
M3323300004
HOSE ASSY........................................................2................S/N 8510247 AND ABOVE
70
0802081003C
RESERVE TANK, 5 LITERS...............................1................REPLACES P/N M9300000203
71
0802010900
CAP, RESERVE TANK........................................1................REPLACES P/N 0602010900
72
M3316100303
BRACKET, RESERVE TANK
1
73
011008020
HEX HEAD BOLT................................................3................REPLACES P/N 0016908020
740199102100 HOSE
1
750193600700 HOSE
1
760193601000 HOSE
1
77
0605515170
HOSE BAND.......................................................3................REPLACES P/N 0605515106
78 M3923200124INTERCOOLER
1
78A M3490202004
ACOUSTIC SHEET
1
79
0132004000
PLUG, 3/8"
1
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 81
ENGINE AND RADIATOR ASSY. (continued)
page 82 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
ENGINE AND RADIATOR ASSY. (continued)
NO.
80
80A
81
82
83
84
85
86
87
88
88A
89
90
91
92
93
94
95
96
97
98
100
101
102
103
PART NO.
M3310202603
M3493114504
012210020
0016906016
M3310502803
M3310502903
0605515208
0605515204
0605515207
M3310600404
0228900320
011206020
M3310303803
M3310303903
011206020
M3310304104
0016906016
M3310304003
011206020
M3326200204
011008020
8121468300
8980274560
1096300850
8971256011
PART NAME
QTY.
REMARKS
BRACKET, INTER COOLER
1
ACOUSTIC SHEET
2
HEX HEAD BOLT................................................8................REPLACES P/N 0017110020
HEX HEAD BOLT
12
COOLER HOSE
1
COOLER HOSE
1
HOSE BAND
2
HOSE BAND
1
HOSE BAND
1
HOSE BRACKET
1
RUBBER SEAL
1
HEX HEAD BOLT................................................1................REPLACES P/N 0016906020
FAN SHROUD
1
FAN SHROUD
1
HEX HEAD BOLT................................................8................REPLACES P/N 0016906020
BRACKET, FAN SHROUD
1
HEX HEAD BOLT
8
FAN GUARD
1
HEX HEAD BOLT................................................6................REPLACES P/N 0016906020
BLOWBY HOSE BRACKET
1
HEX HEAD BOLT................................................1................REPLACES P/N 0016908020
SENSOR, WATER TEMPERATURE
1
SENSOR, OIL PRESSURE
1
GASKET, SENSOR OIL PRESSURE
1
SWITCH, OVERHEAT
1
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 83
OUTPUT TERMINAL ASSY.
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING
ANY PAINTED PANEL TO INDICATE COLOR OF UNIT.
1-ORANGE
2-WHITE
3-SPECTRUM GREY
4-SUNBELT GREEN
5-BLACK
6-CATERPILLAR YELLOW
7-CATO GOLD
8-RED
9-DESERT TAN
THE SERIAL NUMBER MAY BE REQUIRED.
45
46
44
Y
40
43
41
42
page 84 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
OUTPUT TERMINAL ASSY.
NO. PART NO.
PART NAME
QTY.
REMARKS
1
M3230700003
TERMINAL BOARD
1
2
M9220100304
OUTPUT TERMINAL BOLT
5
3
0801830804
TIE BOLT............................................................5................REPLACES P/N M9220100404
4
0039316000
HEX NUT
10
5
0040016000
WASHER, LOCK
15
6
0401450160
WASHER, FLAT.................................................20...............REPLACES P/N 0041416000
7
0012108035
HEX HEAD BOLT................................................5................REPLACES P/N 0016908035
8
M3236101003
TERMINAL COVER
1
9
M3236100404
OUTPUT WINDOW
1
100605010040 HINGE
2
11
0027103010
MACHINE SCREW
4
11A 0207003000
HEX NUT............................................................4................REPLACES P/N 0030003000
11B 58413
WASHER, FLAT..................................................4................REPLACES P/N 0041203000
12
0027103010
MACHINE SCREW
4
12A 0207003000
HEX NUT............................................................4................REPLACES P/N 0030003000
13
M9220100804
SET SCREW
2
13A 0040006000
WASHER, LOCK
2
13B 952404470
WASHER, FLAT..................................................2................REPLACES P/N 0041206000
13C 0080200005
RETAINING RING
2
14
0016906016
HEX HEAD BOLT
4
15
M3236400004
CABLE, OUTLET COVER
1
16
M3236300004
SUPPORTER, CABLE OUTLET COVER
1
17
011206020
HEX HEAD BOLT................................................6................REPLACES P/N 0016906020
18
0601815194
TERMINAL BLOCK
1
19
7538070
MACHINE SCREW.............................................2................REPLACES P/N 0027104016
20
0603306775
BLIND PLUG
2
21
7538070
MACHINE SCREW.............................................4................REPLACES P/N 0027104016
22
0601870440
CIRCUIT BREAKER, 1P 20A.............................2................S/N 9880110 AND BELOW
22
0601808803
CIRCUIT BREAKER, 1P 20A.............................2................S/N 9880111 AND ABOVE
23
0601870441
CIRCUIT BREAKER, 2P 50A.............................3................S/N 9880110 AND BELOW
23
0601808804
CIRCUIT BREAKER, 2P 50A.............................3................S/N 9880111 AND ABOVE
24
M1260700504
BREAKER, FITTING COVER.............................1................S/N 9980110 AND BELOW
24
M1260700304
BREAKER, FITTING COVER.............................1................S/N 9980111 AND ABOVE
24-1 0222100100
CUSHION RUBBER...........................................2................S/N 9980110 AND BE;OW
24-1 0222100150
CUSHION RUBBER...........................................2................S/N 9980111 AND ABOVE
25
011206020
HEX HEAD BOLT................................................2................REPLACES P/N 0016906020
26
0601814013
RECEPTACLE, GF530EM, 125V 20Ax2
2
27
0601814014
RECEPTACLE, CS6369L, 250V 50A
3
28
7538070
MACHINE SCREW............................................10...............REPLACES P/N 0027104016
28A OEMAA8
HEX NUT ..........................................................10...............REPLACES P/N 0207004000
29 M3236400204COVER
1
30
0016906016
HEX HEAD BOLT
8
31
M3236100213
TERMINAL COVER
1
32
012212045
HEX HEAD BOLT................................................2................REPLACES P/N 0010112045
33
031112230
WASHER, FLAT..................................................2................REPLACES P/N 0041212000
34
0805009804
STAY RUBBER...................................................2................REPLACES P/N M9310200004
35
0030012000
HEX NUT
2
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 85
OUTPUT TERMINAL ASSY.
ADD THE FOLLOWING DIGITS AFTER THE PART NUMBER WHEN ORDERING
ANY PAINTED PANEL TO INDICATE COLOR OF UNIT.
1-ORANGE
2-WHITE
3-SPECTRUM GREY
4-SUNBELT GREEN
5-BLACK
6-CATERPILLAR YELLOW
7-CATO GOLD
8-RED
9-DESERT TAN
THE SERIAL NUMBER MAY BE REQUIRED.
45
46
44
Y
40
43
41
42
page 86 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
OUTPUT TERMINAL ASSY.
NO. PART NO.
PART NAME
36 M4236100604COVER
37 M4236400304BRACKET
38
0016906016
HEX HEAD BOLT
39
0019208020
HEX HEAD BOLT
39A 0040508000
TOOTHED WASHER
400601812527 CONNECTOR
410601811177 RECEPTACLE
42
0027104015
MACHINE SCREW
43
M1358200804
WIRE HARNESS, WATER HEATER
44
M3454700004
RUBBER SHEET
45
M3454700104
RUBBER SHEET HOLDER
46
0605053010
SELF DRILLING SCREW
QTY.
1
1
2
1
2
1
1
2
1
1
1
5
REMARKS
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 87
BATTERY ASSY.
page 88 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
BATTERY ASSY.
NO. PART NO.
PART NAME
QTY.
REMARKS
10602220198BATTERY
1
2
M9310500404
BATTERY SHEET
1
3
M9103000504
BATTERY BAND
1
4
0602220921
BATTERY BOLT SET
2
5
M3346901604
BATTERY CABLE
1
6
M3346901504
BATTERY CABLE
1
7
CABLE................................................................1................MAKE LOCALLY
8
0016910025
HEX HEAD BOLT
1
8A
0040510000
TOOTHED WASHER
1
9
0016910025
HEX HEAD BOLT
1
9A
0040508000
TOOTHED WASHER114
1
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 89
Muffler Assy.
page 90 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
Muffler Assy.
NO. PART NO.
PART NAME
QTY.
REMARKS
1 M3330101002MUFFLER
1
2
012212030
HEX HEAD BOLT................................................4................REPLACES P/N 0017112030
3
M3333001603
EXHAUST PIPE
1
41141451840GASKET.............................................................1................REPLACES P/N 0602320108
5 M3333200304GASKET
1
6
0039308000
HEX NUT
8
7
0017110050
HEX HEAD BOLT
4
8 M3330401104COVER
1
9 M3330401003BRACKET
1
10
011008020
HEX HEAD BOLT................................................4................REPLACES P/N 0016908020
11
0602326061
U-BOLT SET
1
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 91
FUEL TANK ASSY.
page 92 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
FUEL TANK ASSY.
NO. PART NO.
1
M3364000203
1-1
0605505072
1-2
0605501074
1-2A0605516090
3
M3364200003
4
0016910025
5
0016910030
6
M2367700003
7
0605515225
9
011008020
10
0222101000
11
0191302200
12
0605515109
13
M3366700203
14
011008020
15
8980139861
15A 8981430410
16
8980758551
16A 8980742880
17
8973834270
18
1096750951
191096300860
20
0015310045
20A 004001000
20B 031110160
21
0010110080
21A 0040010000
21B 031110160
22
8980682750
22A 8980714010
23
011606025
24
0191301790
25
0191300800
26
0191300230
27
0191300850
28
0191300750
29
0605515109
30
0602022791
31
0602022778
32
M3364400004
33
M2484600003
33A M2494600004
340603306792
35
0343708008
35A 0605516091
PART NAME
QTY.
REMARKS
FUEL TANK
1
FUEL TANK CAP
1
FUEL SENDER UNIT
1
GASKET
1
FUEL TANK BRACKET
2
HEX HEAD BOLT
4
HEX HEAD BOLT 4
FUEL FILLER HOSE
1
HOSE BAND
2
HEX HEAD BOLT................................................8................REPLACES P/N 0019208020
TANK SHEET
6
VENT HOSE
1
HOSE BAND
2
FUEL FILTER BRACKET
1
HEX HEAD BOLT................................................4................REPLACES P/N 0016908020
FUEL FILTER ASSY.(MAIN)...............................1................REPLACES P/N 0602042426
ELEMENT, FUEL FILTER...................................1................REPLACES P/N 0602042515
FUEL FILTER ASSY.(PRE.)................................1................REPLACES P/N 0602042405
ELEMENT, FUEL FILTER...................................1................REPLACES P/N 0602042516
JOINT PIPE........................................................4................REPLACES P/N 0602042661
JOINT BOLT........................................................4................REPLACES P/N 0602042621
PACKING............................................................8................REPLACES P/N 0602042641
HEX HEAD BOLT
4
SPRING WASHER
4
PLAIN WASHER.................................................4................REPLACES P/N 004121000
HEX HEAD BOLT
2
WASHER, LOCK
2
WASHER, FLAT..................................................2................REPLACES P/N 0041210000
FUEL FEED PUMP.............................................1................REPLACES P/N 0602023240
FUEL FILTER......................................................1................REPLACES P/N 0602042517
HEX HEAD BOLT................................................2................REPLACES P/N 0016906025
SUCTION HOSE
1
SUCTION HOSE
1
SUCTION HOSE
1
SUCTION HOSE
1
RETURN HOSE
1
HOSE BAND
10
HOSE JOINT
2
HOSE JOINT
2
PICKUP TUBE
2
FUEL FILLER BRACKET
1
ACOUSTIC SHEET
1
PLUG
1
HEX HEAD BOLT
5
SEALING WASHER
5
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 93
ENCLOSURE ASSY. PART 1.
page 94 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
ENCLOSURE ASSY. PART1.
NO. PART NO.
PART NAME
QTY.
REMARKS
1 M3414000102BASE
1
2
M3364300003
ENVIRONMENTAL TANK
1
3
0016910030
HEX HEAD BOLT
12
4
0603306797
PLUG, 1-1/2"
1
5
M3423002802
FRONT FRAME
1
5A
M3493114403
ACOUSTIC SHEET
1
6
M3423002902
FRONT FRAME
1
6A
M3493114403
ACOUSTIC SHEET
1
70601851765GROMMET
1
8
011008020
HEX HEAD BOLT...............................................27...............REPLACES P/N 0016908020
9
M3423003003
FRONT FRAME
1
10
011008020
HEX HEAD BOLT................................................8................REPLACES P/N 0016908020
11
0016910025
HEX HEAD BOLT
6
12
M3310400403
HOSE COVER
1
13
011206020
HEX HEAD BOLT................................................7................REPLACES P/N 0016906020
14
M3310400304
HOSE COVER
1
15
011206020
HEX HEAD BOLT................................................8................REPLACES P/N 0016906020
16 M3423500204BRACKET
1
17
011008020
HEX HEAD BOLT................................................2................REPLACES P/N 0016906020
18
M3423200704
DUCT COVER
2
19
011206020
HEX HEAD BOLT...............................................14...............REPLACES P/N 0016906020
20
M3310302704
SHROUD BRACKET
1
21
0016906016
HEX HEAD BOLT
6
22
M3423300304
DISCHARGE GUIDE
1
22A M3493113704
ACOUSTIC SHEET
1
23
011008020
HEX HEAD BOLT................................................4................REPLACES P/N 0019208020
24
M3423202603
COVER FRONT FRAME
1
24A M3493111803
ACOUSTIC SHEET
1
25
M3423202403
FRONT LOUVER
1
26
0019206016
HEX HEAD BOLT
6
27
011008020
HEX HEAD BOLT................................................4................REPLACES P/N 0019208020
28
011008020
HEX HEAD BOLT................................................4................REPLACES P/N 0016908020
29
M3434000102
CENTER FRAME
1
29A M3493201304
ACOUSTIC SHEET
1
30
0010114040
HEX HEAD BOLT
4
30A 515455840
HEX NUT............................................................4................REPLACES P/N 0030014000
30B 030214350
WASHER, LOCK................................................4................REPLACES P/N 0040014000
30C 0041220000
WASHER, FLAT
8
31
0010120050
HEX HEAD BOLT
4
31A 0030020000
HEX NUT
4
31B 030220510
WASHER, LOCK................................................4................REPLACES P/N 0040020000
31C 0041220000
WASHER, FLAT
8
32
M3463101503
ROOF PANEL
1
32A M3493509204
ACOUSTIC SHEET
1
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 95
ENCLOSURE ASSY. PART 1 (continued)
page 96 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
ENCLOSURE ASSY. PART 1 (continued)
NO. PART NO.
PART NAME
QTY.
REMARKS
33
M3463202202
ROOF PANEL
1
33A M3493509303
ACOUSTIC SHEET
1
34
M3463201104
BACK PLATE
2
35
0016906016
HEX HEAD BOLT
12
36 M3463202303DUCT
1
36A M3493506004
ACOUSTIC SHEET
1
37
011008020
HEX HEAD BOLT................................................8................REPLACES P/N 0016908020
38
M3423202704
OVER COVER, FRONT FRAME
1
38A M3493108004
ACOUSTIC SHEET
1
39
011008020
HEX HEAD BOLT...............................................51...............REPLACES P/N 0019208020
40
0017110025
HEX HEAD BOLT................................................8................REPLACES P/N 0019210025
41
M3310600004
COVER, RADIATOR CAP
1
42
011008020
HEX HEAD BOLT................................................4................REPLACES P/N 0019208020
43
011008020
HEX HEAD BOLT................................................1................REPLACES P/N 0019698020
43A 0040508000
TOOTHED WASHER
1
44
0605503062
FUEL LEAK DETECTED SWITCH
1
45 M1414800104BRACKET
1
46
011008020
HEX HEAD BOLT................................................2................REPLACES P/N 0016908020
470603306793 PLUG
1
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 97
ENCLOSURE ASSY. PART 2.
page 98 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
ENCLOSURE ASSY. PART 2.
NO. PART NO.
PART NAME
QTY.
REMARKS
1
M3444000102
REAR FRAME
1
1A
M3493308603
ACOUSTIC SHEET
1
2 M3443002004DUCT
2
3
011008020
HEX HEAD BOLT...................................................6................. REPLACES P/N 0016908020
4
M3443400103
PANEL, REAR FRAME
1
4A
M3493308904
ACOUSTIC SHEET
1
4-1
0314501550
RUBBER SEAL
1
4-20330000250 EDGING
1
4-30330000325 EDGING
1
5
011008020
HEX HEAD BOLT...................................................6................. REPLACES P/N 0016908020
6 M3443002103DUCT
1
6A
M3493308804
ACOUSTIC SHEET
1
7 M3443002203DUCT
1
7A
M3443008804
ACOUSTIC SHEET
1
8
011008020
HEX HEAD BOLT...................................................6................. REPLACES P/N 0016908020
9
011008020
HEX HEAD BOLT...................................................6................. REPLACES P/N 0016908020
10
0016910025
HEX HEAD BOLT
4
11
M3444300203
COVER, REAR FRAME
1
11A M3493308704
ACOUSTIC SHEET
2
12
011008020
HEX HEAD BOLT...................................................4................. REPLACES P/N 0019208020
13
011008020
HEX HEAD BOLT...................................................4................. REPLACES P/N 0019208020
14
M3444200103
DOOR, REAR FRAME
1
15
M3443600304
WINDOW PLATE
1
16
0207306000
HEX NUT
8
16A 952404470
WASHER, FLAT..................................................8................REPLACES P/N 0041206000
17
0605012309
DOOR HANDLE ASSY
1
18
0176060030
HEX NUT............................................................4................REPLACES P/N 0207006000
19 M9110100204HINGE
2
20 M9116100004WASHER
2
21
011008020
HEX HEAD BOLT...................................................3................. REPLACES P/N 0019208020
22
M3454200202
SPLASHER PANEL............................................1................S/N 9980110 AND BELOW
22
M3454200212
SPLASHER PANEL............................................1................S/N 9980111 AND ABOVE
22A M3493426704
ACOUSTIC SHEET
1
23
0019108065
HEX HEAD BOLT
4
23A 0042308000
WASHER, LOCK
4
23B 0042408000
WASHER, FLAT
4
24
0016910025
HEX HEAD BOLT
2
25
M3454000503
SIDE DOOR
1
25A M3493426504
ACOUSTIC SHEET
1
26
M3454000603
SIDE DOOR
1
26A M3493426504
ACOUSTIC SHEET
1
27
M3454000703
SIDE DOOR
1
27A M3493417204
ACOUSTIC SHEET
1
28
M3454000403
SIDE DOOR
1
28A M3494405804
ACOUSTIC SHEET
1
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 99
ENCLOSURE ASSY. PART 2 (continued)
page 100 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
ENCLOSURE ASSY. PART 2 (continued)
NO. PART NO.
PART NAME
QTY.
REMARKS
29
0605012309
DOOR HANDLE ASSY
4
29A C9312500004
SEAL RUBBER
4
30
00176060030
HEX NUT...........................................................16...............REPLACES P/N 0207006000
30A 020106050
HEX NUT...........................................................16...............REPLACES P/N 0030006000
310845046904 HINGE.................................................................6................REPLACES P/N M9110100804
320845047004 HINGE.................................................................5................REPLACES P/N M9110100904
33 M9116100004WASHER
11
34
011008020
HEX HEAD BOLT...............................................26...............REPLACES P/N 0019208020
350601850097 STOPPER
8
36
0027208025
MACHINE SCREW
8
37 M9310000004CAP
13
38
0600800320
MANUAL PACK
1
39
0021806016
MACHINE SCREW
4
40
M3454100003
SIDE PANEL
1
40A M3494405904
ACOUSTIC SHEET
1
41
0019108065
HEX HEAD BOLT
4
41A 0042308000
WASHER, LOCK
4
41B 031108160
WASHER, FLAT
4
42
0016910025
HEX HEAD BOLT
2
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 101
RUBBER SEALS ASSY.
page 102 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
RUBBER SEALS ASSY.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
PART NO.
0229200870
0229201130
0229201240
0228901070
0314502700
0229200125
0228901165
0228900925
0228901105
0228900565
0228900945
0228900505
0229201090
0229201335
0228901335
0228900655
0229201090
0228100630
0229401080
0228800565
0228801080
0228800545
0228100370
0228100640
0228900700
0228900640
0229200295
0229200220
PART NAME
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
RUBBER SEAL
QTY.
1
1
3
1
1
4
3
4
3
1
4
1
1
2
1
1
1
2
1
1
1
1
2
2
1
1
2
2
REMArks
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 103
battery charger ASSY. (OPTION)
CONNECT TO
ENGINE GROUND
1
8
9
CONNECT TO
STARTER
2
3
5
4
6
7
OUTPUT TERMINAL
PANEL COVER
page 104 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
battery charger ASSY. (OPTION)
NO. PART NO.
1
LC125002
2
3
4
5
6
HBL5369C
7
EE56557
8
9
PART NAME
QTY.
REMARKS
CHARGER BATTERY, 3 AMP 12V.....................1
GROMMENT, 7/8" HOLE SIZE...........................1................OBTAIN LOCALLY
WASHER, FLAT M4............................................4................OBTAIN LOCALLY
WASHER, LOCK M4..........................................4................OBTAIN LOCALLY
SCREW, M4X10.................................................4................OBTAIN LOCALLY
CONNECTOR, 20 AMP ,125V
1
CORD, 3-CONDUCTOR, 14 AWG, 10 FT.
1
WIRE, 16GA, GREEN..................................... 9 FT...............OBTAIN LOCALLY
WIRE, 16GA, RED ......................................... 9 FT...............OBTAIN LOCALL
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 105
jacket water heater ASSY.
7
4
3
5
5
6
2
1
9
8
1 10
10 1
5
15
11 1
5
EXISTING DRAIN
HOSE RELOCATED
TO TEE FITTING
12
7
13
14 1
NOTICE
Some of the components shown may not be required..
NOTES:
1
INCLUDED WITH ITEM 8,
JACKET WATER HEATER.
16
17
OUTPUT TERMINAL
PANEL COVER
page 106 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
jacket water heater ASSY.
NO. PART NO.
1
2
3
4
5
0605515198
6
0269301000
7
8
TPS101GT10000
9
10#
11#
12
0011206020
13
0176060030
14# EE1266
15
0269301100
16
EE56557
17
HBL5369C
PART NAME
QTY.
REMARKS
1/4" MP X 5/16 HB NIPPLE................................1................OBTAIN LOCALLY
1/4 X 1/4 1/4" FEMALE PIPE TEE......................1................OBTAIN LOCALLY
1/4 X 1/4 MALE TO MALE PIPE NIPPLE...........1................OBTAIN LOCALLY
3/8" MP X 5/8 HB 90° ELBOW............................1................OBTAIN LOCALLY
HOSE CLAMP
4
HEATER HOSE (TOP)
1
SPLIT LOOM, 1" X 20".......................................2................OBTAIN LOCALLY
HEATER, 1000W, 120 VAC.................................1................INCLUDES ITEMS W/#
1/4" MP X 5/8" HB 90° ELBOW..........................1................OBTAIN LOCALLY
BOLT, 1/4"-20 X 1"
4
WASHER, FLAT 1"
4
HEX HEAD BOLT................................................2................REPLACES P/N 0019206020
HEX NUT............................................................2................REPLACES P/N 0207006000
BRACKET, HOT START
1
HEATER HOSE (BOTTOM)
1
CORD, 3-CONDUCTOR, 14 AWG, 2 FT. 1
CONNECTOR, 20 AMP ,125V
1
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 107
NAMEPLATE AND DECALS ASSY.
8 - 11A
3 - 6A
9-2
9-2A
9-6
9-6A
2 - 9A
9-6A
9-6
A
3-4A
10
1-3
9-2A
9-2
A
9-2A
4-6A
9-2
4-6
4-6
4-3A
8-1
4-1A
DECAL KIT
4-9
4-8A
11
4-4
TRAILER
4-7A
9-1
6-1A
3-7A
DECAL KIT
9-1A
3-4A
5-3A
9-3
1-1
1-1A
1-1A
2-8A
1-2A
8-9A
8-9
9-7 12
9-7A
9-3A
9-5A
9-5
8-12A
page 108 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
NAMEPLATE AND DECALS ASSY.
NO. PART NO.
1-1
M3550003003
1-1A EE57081
1-2
M9520100304
1-2A#
1-3
M9520100603
1-3A#
2-1
M3550003503
2-2
M3550003603
2-3
M9520000104
2-4
M9520000204
2-5
M9520000804
2-6
M9520000904
2-7
M9520001104
2-8
M9520100004
2-8A#
2-9
M9520100204
2-9A#
2-10 M9520200404
2-11 M9520002104
2-12 M9531000004
3-1
M9500000004
3-2
M9500100004
3-3
M9500100304
3-4
M9503000004
3-4A#
3-5
M9503000103
3-6
M9503100004
3-6A#
3-7
M9510100004
3-7A#
4-1
EE57066
4-1A EE57067
4-2
M1550002203
4-3
EE57082
4-3A EE57083
4-4
M9520000004
4-5
M9520000504
4-6
M9520100004
4-6A#
4-7
M9520100404
4-7A# EE58330
4-8
M9520100503
4-8A#
4-9
M9520200003
PART NAME
QTY.
REMARKS
DECAL: OPERATING PROCEDURES (ENGLISH) .................. 1............ M35000300A
DECAL: OPERATING PROCEDURES (FRENCH)
1
DECAL: SAFETY INSTRUCTIONS (ENGLISH)........................ 1............ M92010030
DECAL: SAFETY INSTRUCTIONS (FRENCH)........................1............B92110040CE
DECAL: CAUTION, START/STOP (ENGLISH).......................... 2............ M92010060
DECAL: CAUTION, START/STOP (FRENCH)........................... 1............ MQC92210000CE
DECAL: CONTROL PANEL....................................................... 1............ M35000350
DECAL: OPERATING PANEL.................................................... 1............ M35000360
PLATE: AMMETER CHANGE- OVER SWITCH........................ 1............ M92000010
PLATE: VOLTMETER CHANGE- OVER SWITCH..................... 1............ M92000020
DECAL: AC................................................................................ 1............ M92000080
DECAL: DIAGNOSTIC SWITCH............................................... 1............ M92000090
DECAL: DIAGNOSTIC BUTTON............................................... 1............ M92000110
DECAL: WARNING, ELECTRIC SHOCK HAZ. (ENGLISH)...... 1............ M92010000
DECAL: WARNING, ELECTRICAL SHOCK HAZ.(FRENCH)... 1............ MQB9310050CE
DECAL: CAUTION, STOP ENGINE (ENGLISH)....................... 1............ M92010020A
DECAL: CAUTION, STOP ENGINE (FRENCH)....................... 1............M92010020CE
DECAL: OVER CURRENT RELAY............................................ 1............ M92020040
DECAL:FUEL PUMP SWITCH.................................................. 1............ M92000210
DECAL:NOTICE, TEMPERATURE GUAGE.............................. 1............ M93100000
DECAL : OIL DRAIN PLUG....................................................... 1............ M90000000
DECAL : WATER........................................................................ 1............ M90010000
DECAL : INTER-COOLER DRAIN............................................. 1............ M90010030
DECAL : WARNING, MOVING PARTS (ENGLISH)................... 2............ M90300000
DECAL : WARNING, MOVING PARTS (FRENCH)....................2............M90300000CE
DECAL : WATER - OIL CHECK................................................. 1............ M90300010
DECAL : WARNING, HOT COOLANT (ENGLISH).................... 1............ M90310000
DECAL : WARNING, HOT COOLANT (FRENCH)..................... 1............ M9031000CE
DECAL : CAUTION, HOT PARTS (ENGLISH)........................... 1............ M91010000
DECAL : CAUTION, HOT PARTS (FRENCH)............................ 1............ MQB90400030CE
DECAL : NOTICE, 50 AMP RECEPTACLES (ENGLISH)
.1
REP. P/N M1550000204
DECAL : NOTICE, 50 AMP RECEPTACLES (FRENCH)
1
DECAL : RECEPT. AND CIRCUIT BREAKER, ......................... 1............ M15000220
DECAL : NOTICE, LOAD SHARING (ENGLISH)...................... 1............ M35000000
DECAL : NOTICE, LOAD SHARING (FRENCH)....................... 1............ EE57083
DECAL : GROUND.................................................................... 1............ M92000000
DECAL : START CONTACT....................................................... 1............ M92000050
DECAL : WARNING, ELECTRIC SHOCK HAZ. (ENGLISH)..... 1............ M92010000
DECAL : WARNING, ELECTRICAL SHOCK HAZ.(FRENCH).. 1............ MQB9310050CE
DECAL : DANGER, HIGH VOLTAGE (ENGLISH)...................... 1............ M92010040
DECAL : DANGER, HIGH VOLTAGE (FRENCH)....................... 1............ MQS-2731CE
DECAL : WARNING, ELECTRICAL (ENGLISH)........................1............ M92010050
DECAL : WARNING, ELECTRICAL (FRENCH)........................ 1............ M92010050CE
DECAL : OUTPUT TERMINAL.................................................. 1............ M92020000
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 109
NAMEPLATE AND DECALS ASSY. (continued)
8 - 11A
3 - 6A
9-2
9-2A
9-6
9-6A
2 - 9A
9-6A
9-6
A
3-4A
10
1-3
9-2A
9-2
A
9-2A
4-6A
9-2
4-6
4-6
4-3A
8-1
4-1A
DECAL KIT
4-9
4-8A
11
4-4
TRAILER
4-7A
9-1
6-1A
3-7A
DECAL KIT
9-1A
3-4A
5-3A
9-3
1-1
1-1A
1-1A
2-8A
1-2A
8-9A
8-9
9-7 12
9-7A
9-3A
9-5A
9-5
8-12A
page 110 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
NAMEPLATE AND DECALS ASSY. (continued)
NO. PART NO.
PART NAME
QTY.
REMARKS
5-1
M9500300004
DECAL : -................................................................................... 1............ M90030000
5-2
M9500300104
DECAL : +.................................................................................. 1............ M90030010
5-3
M9510100403
DECAL : CAUTION, OFF/RESET SW (ENGLISH).....................1............ M91010040
5-3A#
DECAL : CAUTION, OFF/RESET SW (FRENCH)..................... 1............ MQC90530000CE
6-1
M9503200004
DECAL : WARNING, ENGINE EXHAUST (ENGLISH).............. 1............ M90320000
6-1A#
DECAL : WARNING, ENGINE EXHAUST (FRENCH)............... 1............ MQB90420000CE
7-1
M9500500004
DECAL : DIESEL FUEL............................................................. 1............ M90050000
7-2
M9510000004
DECAL : FUEL DRAIN PLUG.................................................... 1............ M91000000
8-1
M9512200004
DECAL : MQ.............................................................................. 1............ M91220000
8-2
M9510200304
DECAL : MQ POWER
2
8-3M3560102004 STRIPE
2
8-4
M3560102103
STRIPE : WHISPERWATT
2
8-5M3560102204 STRIPE
2
8-6
M3560102303
STRIPE : 125
1
8-7
M3560102403
STRIPE : 125
1
8-8M3560102504 STRIPE
2
8-9
EE57068
DECAL: NOTICE, ENVIRONMENTAL WARNING (ENGLISH).. 1............ REP. P/NM9510100304
8-9A EE57069
DECAL: NOTICE, ENVIRONMENTAL WARNING (FRENCH)... 1............ EE57069
8-10 0600500092
PLATE : MQ POWER
1
8-10A 0021106016
MACHINE SCREW
4
8-11 M3550002204
DECAL : CAUTION, BAIL MAX CAPACITY (ENGLISH)............ 1............ M35000220
8-11A# DECAL : CAUTION, BAIL MAX CAPACITY (FRENCH) 1
8-12 M9503200104
DECAL : DANGER, EXHAUST GAS (ENGLISH)...................... 1............ M90320010
8-12A#
DECAL : DANGER, EXHAUST GAS (FRENCH)....................... 1............ M90320010CE
8-13 M9510000104
DECAL : DOCUMENT BOX LOCATED..................................... 1............ M91000010
9-1
49002
DECAL: WARNING, TRAILER (ENGLISH)
1
9-1A#
DECAL: WARNING, TRAILER (FRENCH)................................ 1............ 490002CE
9-2$ EE57072
DECAL: NOTICE, BONDED TO FRAME (ENGLISH)
2
9-2A$ EE57073
DECAL: NOTICE, BONDED TO FRAME (FRENCH)
2
9-3$ EE57075
DECAL: NOTICE, CLASS F (ENGLISH)
1
9-3A$ EE57076
DECAL: NOTICE, CLASS F (FRENCH)
1
9-5$ EE57070
DECAL: NOTICE, OVERLOAD (ENGLISH)
1
9-5A$ EE57071
DECAL: NOTICE, OVERLOAD (FRENCH)
1
9-6$ EE57079
DECAL: NOTICE, SUPPLY WIRES (ENGLISH)
1
9-6A$ EE57080
DECAL: NOTICE, SUPPLY WIRES (FRENCH)
1
9-7
920214100
DECAL: WARNING, SPARKS (ENGLISH)
1
9-7A#
DECAL: WARNING, SPARKS (FRENCH)................................. 1............ M9042000CE
10
EE52657
DECAL KIT (FRENCH).............................................................. 1............ INCLUDES ITEMS W/ #
11
EE57074
DECAL KIT (ENGLISH & FRENCH).......................................... 1............ INCLUDES ITEMS W/ $
12
EE57090
NAME PLATE, EMISSION CONTROL (ENGLISH & FRENCH) 1
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 111
3ø 600 vac Transformer ASSY. (OPTION)
3
4
5
7
2
1
9
6
19
1
8
18
17
10
19
15
18A
1
16
BACKSIDE OF DOOR
11
10
11A
14
12
13
11B
11C
page 112 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
3ø 600 vac Transformer ASSY. (OPTION)
NO. PART NO.
1
EE5981
2
EE57551
3
EE57550
4
EE52422
5
EE57532
6EE57533
7
EE57770
8$
9
EE57534
10
EE50115
11
11A
11B
11C
12
EE57768
13
EE57424
14
EE57387
15
EE16322
16
EE57546
17
EE57608
18
18A
19
EE57549
PART NAME
QTY.
REMARKS
BUSHING, PLASTIC, 2"
4
KIT, NEUTRAL, T3NK2525
1
ENCLOSURE, NEMA 3R CIRCUIT BREAKER
1
CIRCUIT BREAKER, T3N0125TW
1
MECHANISM, CIRCUIT BREAKER OPERATION
1
SHAFT
1
LABEL, VINYL, 600V
1
SCREW
2
HANDLE, EXTERIOR................................................................ 1............ INCLUDES ITEM W/ $
CONNECTOR, 90°, LIQUID TIGHT FITTING 2"
2
BOLT, 1/2" X 1-3/4" GRD 8........................................................ 4............ OBTAIN LOCALLY
WASHER, FLAT, 1/2"................................................................. 4............ OBTAIN LOCALLY
WASHER, LOCK, 1/2"............................................................... 4............ OBTAIN LOCALLY
NUT, HEX 1/2"........................................................................... 4............ OBTAIN LOCALLY
LABEL, VINYL, DIAGRAM
1
TRAY TRANSFORMER
1
TRANSFORMER, 600V, 3-PHASE, 125 KVA
1
CONDUIT, LIQUID TIGHT FLEXIBLE 2".................................. 10........... 1PC = 1FT
CABLE, 1/0 AWG SIM PULL THHN/90 BLACK....................... 112.......... 1PC = 1FT
BRACKET, MTG. FOR CONDUIT, ALUMINUM
1
BOLT, M6 X 20........................................................................... 1............ OBTAIN LOCALLY
NUT, M6..................................................................................... 2............ OBTAIN LOCALLY
STRAIGHT, LIQUID TIGHT FITTING
2
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 113
Terms and Conditions of Sale — Parts
paYmeNt termS
5.
Parts must be in new and resalable
condition, in the original Multiquip
package (if any), and with Multiquip part
numbers clearly marked.
6.
The following items are not returnable:
Multiquip reserves the right to quote and
sell direct to Government agencies, and to
Original Equipment Manufacturer accounts
who use our products as integral parts of their
own products.
a.
SpeCIal expeDItINg ServICe
Terms of payment for parts are net 30 days.
FreIght polICY
All parts orders will be shipped collect or
prepaid with the charges added to the invoice.
All shipments are F.O.B. point of origin.
Multiquip’s responsibility ceases when a
signed manifest has been obtained from the
carrier, and any claim for shortage or damage
must be settled between the consignee and
the carrier.
b.
mINImUm orDer
The minimum charge for orders from Multiquip
is $15.00 net. Customers will be asked for
instructions regarding handling of orders not
meeting this requirement.
retUrNeD gooDS polICY
Return shipments will be accepted and
credit will be allowed, subject to the following
provisions:
1.
A Returned Material Authorization
must be approved by Multiquip prior to
shipment.
2.
Obsolete parts. (If an item is in the
price book and shows as being
replaced by another item, it is
obsolete.)
Any parts with a limited shelf life
(such as gaskets, seals, “O” rings,
and other rubber parts) that were
purchased more than six months
prior to the return date.
c.
Any line item with an extended
dealer net price of less than
$5.00.
d.
Special order items.
e.
Electrical components.
f.
Paint, chemicals, and lubricants.
g.
Decals and paper products.
h.
Items purchased in kits.
7.
The sender will be notified of any material
received that is not acceptable.
To obtain a Return Material Authorization,
a list must be provided to Multiquip
Parts Sales that defines item numbers,
quantities, and descriptions of the items
to be returned.
8.
Such material will be held for five
working days from notification, pending
instructions. If a reply is not received
within five days, the material will be
returned to the sender at his expense.
a.
The parts numbers and descriptions
must match the current parts price
list.
9.
b.
The list must be typed or computer
generated.
Credit on returned parts will be issued
at dealer net price at time of the original
purchase, less a 15% restocking
charge.
c.
The list must state the reason(s)
for the return.
d.
The list must reference the sales
order(s) or invoice (s) under
which the items were originally
purchased.
e.
The list must include the name
and phone number of the person
requesting the RMA.
3.
A copy of the Return Material Authorization
must accompany the return shipment.
4.
Freight is at the sender’s expense. All
parts must be returned freight prepaid to
Multiquip’s designated receiving point.
10. In cases where an item is accepted, for
which the original purchase document
can not be determined, the price will be
based on the list price that was effective
twelve months prior to the RMA date.
A $35.00 surcharge will be added to the
invoice for special handling including bus
shipments, insured parcel post or in cases
where Multiquip must personally deliver the
parts to the carrier.
lImItatIoNS oF Seller’S lIaBIlItY
Multiquip shall not be liable hereunder for
damages in excess of the purchase price of
the item with respect to which damages are
claimed, and in no event shall Multiquip be
liable for loss of profit or good will or for any
other special, consequential or incidental
damages.
lImItatIoN oF WarraNtIeS
No warranties, express or implied, are
made in connection with the sale of parts or
trade accessories nor as to any engine not
manufactured by Multiquip. Such warranties
made in connection with the sale of new,
complete units are made exclusively by a
statement of warranty packaged with such
units, and Multiquip neither assumes nor
authorizes any person to assume for it
any other obligation or liability whatever in
connection with the sale of its products. Apart
from such written statement of warranty,
there are no warranties, express, implied or
statutory, which extend beyond the description
of the products on the face hereof.
Effective: February 22, 2006
11. Credit issued will be applied to future
purchases only.
prICINg aND reBateS
Prices are subject to change without prior
notice. Price changes are effective on a
specific date and all orders received on or
after that date will be billed at the revised price.
Rebates for price declines and added charges
for price increases will not be made for stock
on hand at the time of any price change.
page 114 — DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14)
notes
DCA125USI3CAN 60 hz Generator • operation and parts manual — rev. #3 (12/19/14) — page 115
Operation and Parts Manual
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING
United StateS
Multiquip Corporate Office
18910 Wilmington Ave.
Carson, CA 90746
Contact: [email protected]
MQ Parts Department
Tel. (800) 421-1244
Fax (310) 537-3927
Service Department
800-421-1244
310-537-3700
800-427-1244
310-537-3700
Fax: 800-672-7877
Fax: 310-637-3284
Warranty Department
Fax: 310-537-4259
800-421-1244
310-537-3700
Fax: 310-943-2249
Technical Assistance
800-478-1244
Fax: 310-943-2238
Canada
United Kingdom
Multiquip
Multiquip (UK) Limited Head Office
4110 Industriel Boul.
Laval, Quebec, Canada H7L 6V3
Contact: [email protected]
Tel: (450) 625-2244
Tel: (877) 963-4411
Fax: (450) 625-8664
Unit 2, Northpoint Industrial Estate,
Globe Lane,
Dukinfield, Cheshire SK16 4UJ
Contact: [email protected]
Tel: 0161 339 2223
Fax: 0161 339 3226
© COPYRIGHT 2014, MULTIQUIP INC.
Multiquip Inc, the MQ logo and the MQ Power logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other
trademarks are the property of their respective owners and used with permission.
This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if resold.
The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical data contained in
this manual are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change specifications, design or the information published
in this publication at any time without notice and without incurring any obligations.
Your Local Dealer is:
Manufactured for
Multiquip Inc.
by
DENYO CO., LTD, JAPAN